Fluid-structure interaction simulation based physicochemical synergistic removal modeling and process optimization...

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Optical Engineering

Background:

• Wheel-type elastic emission machining (EEM) is a promising technique for atomic-level, low-damage optical fabrication.
• Existing material removal models do not capture the complex physicochemical mechanisms of EEM, hindering deterministic process control.

Purpose of the Study:

• To develop a synergistic material removal model for wheel-type EEM that accounts for coupled physicochemical phenomena.
• To establish an optimal process window for deterministic control and high-quality optical surface fabrication.

Main Methods:

• Developed a physicochemical synergistic material removal model for wheel-type EEM.
• Constructed a 3D fluid-structure interaction (FSI) simulation to analyze fluid dynamics and wheel deformation.
• Conducted experimental investigations to validate the model and analyze process parameter sensitivity.

Main Results:

• The developed model accurately predicts removal profiles, with R² > 0.99 compared to experimental data.
• Identified a three-stage nonlinear relationship between removal depth and polishing parameters (speed, time, gap).
• Polishing time was found to be the most significant factor influencing removal depth, followed by gap and speed.

Conclusions:

• The physicochemical synergistic model provides accurate predictions for wheel-type EEM.
• An optimal process window was established, balancing high removal efficiency with disturbance rejection.
• This work offers crucial guidance for applying EEM in ultra-precision optical surface manufacturing.