Mechanistic insights and modeling of tool mark removal in fluid jet polishing for ultra-precision machining

Abstract

Tool marks, which are unavoidable surface defects in ultra-precision machining processes such as milling, grinding, and turning, can significantly degrade the performance of high-end components. Therefore, the elimination of these marks to achieve a smooth finish is imperative. Fluid jet polishing has emerged as a promising technique owing to its shape-adaptive characteristics, which allow for effective application on both freeform and structured surfaces while ensuring high dimensional accuracy. However, the underlying mechanism of tool mark removal in fluid jet polishing remains poorly understood, posing a challenge to predicting its efficacy. Currently, the effectiveness of tool mark removal is primarily evaluated through laborious trial-and-error experimentation. This study seeks to elucidate the mechanism of tool mark removal in fluid jet polishing to enhance its efficacy. A physical model was established to simulate the abrasive erosion selectivity and the evolution of tool mark morphologies. A comprehensive set of experiments was conducted to validate the model's accuracy. By leveraging this physical model, manufacturers can gain critical insights into the tool mark removal process and make informed decisions to optimize the parameters in fluid jet polishing. Ultimately, this research advances the quality and performance of high-end components in ultra-precision machining.