High-Efficiency Precision Polishing Using Fiber Brush-Shear-Thickening Fluid Composites

Shear-thickening fluid (STF) is widely applied in various practical engineering fields due to its rheological properties of increased viscosity under load. We investigated the integration of STF with fiber brushes to prepare a novel composite material for polishing applications. The impact of composite material properties is studied in surface finish, specifically roughness and morphology, across flat and uneven surfaces. The effects of the critical variables, including polishing speed, feed depth, and STF concentration, are analyzed through experimentation and simulation. After the STF polishing, the surface roughness of the aluminum alloy sample decreases from 3.125 μm to 0.528 μm, which increases the processing efficiency by 40% compared to Newton polishing slurry. The unique shear-thickening performance of the composite material ensures excellent surface quality and high efficiency in the precision machining of workpieces.