Process Parameter Modeling and Optimization of Abrasive Water Jet Dressing Fixed-Abrasive Pad Based on Box-Behnken...

Area of Science:

• Materials Science
• Manufacturing Engineering
• Surface Metrology

Background:

• Online controllable dressing of fixed-abrasive pads (FAPs) using abrasive water jets requires understanding process parameter influences.
• Optimizing dressing effects is essential for efficient and precise machining operations.

Purpose of the Study:

• To investigate the impact of abrasive water jet dressing parameters on FAP dressing quality.
• To establish a predictive model for material removal rate (MRR) based on key process variables.
• To determine optimal parameters for maximizing FAP dressing performance.

Main Methods:

• Utilized a three-factor, three-level response surface methodology to analyze process variables.
• Explored the influence of jet pressure, abrasive concentration, and nozzle angle on FAP dressing.
• Developed and validated a predictive model for MRR.

Main Results:

• Identified optimal dressing parameters: jet pressure at 3.8 MPa, abrasive concentration at 3%, and nozzle angle at 73°.
• The predictive model achieved a high accuracy, with a predicted optimal MRR of 464.574 nm/min.
• Experimental verification confirmed the model's predictions, yielding an MRR of 469.136 nm/min with minimal error.

Conclusions:

• The established response surface model accurately predicts FAP dressing performance.
• The identified optimal parameters provide a foundation for online controllable abrasive water jet dressing.
• Achieved precise control over the dressing process, enhancing material removal efficiency and surface quality.