磁流变抛光液流变学特性测试方法及仿真建模

doi:10.16183/j.cnki.jsjtu.2024.326

摘要/Abstract

摘要：

磁流变抛光在非球面光学镜片超精密加工等领域具有广阔的应用前景.通过磁场仿真设计合理的磁极尺寸,优化测试磁场的均匀度和垂直度,设计适用于HR20型旋转流变仪的磁流变测试套件及方法,结合实验测试和理论拟合确定了最佳流体本构模型;建立轮式磁流变抛光流场模型,分析磁场强度对磁流变抛光液黏度、抛光缎带形貌、抛光区域压力分布的影响规律.测试结果表明,抛光液黏度随外磁场强度增加而显著增大;流场仿真结果表明,磁场影响下抛光缎带会发生收束,与工件有效接触面积增大,在工件表面产生的“D”形压力分布随外磁场增强而显著增强,有助于改善工件的加工效果.

关键词: 磁流变抛光液, 抛光缎带, 流变学性能, 本构模型, 数值仿真

Abstract:

Magnetorheological finishing method has broad application prospects in the fields of ultra-precision processing of aspherical optical lenses. Through magnetic field simulation, rational magnet pole dimensions were designed to optimize the uniformity and perpendicularity of the test magnetic field. A magnetorheological test kit for the HR20 rheometer and a matching test method were designed and optimized, and the best constitutive model was found through experimental testing and curve fitting. A wheel-type magnetorheological polishing flow field model was established, and the influence of magnetic field intensity on the viscosity of magnetorheological polishing fluid, the morphology of polishing ribbon, and the pressure distribution in the polishing area were analyzed. The test results show that the viscosity of the polishing fluid increase significantly with the increase of the external magnetic field intensity. The flow field simulation results show that the polished ribbon converges under the influence of the magnetic field, and the effective contact area with the workpiece increases. The “D”-shaped pressure distribution generated on the surface of the workpiece is significantly enhanced as the external magnetic field increases.

Key words: magnetorheological polishing fluid, polishing ribbon, rheological properties, constitutive model, numerical simulation

中图分类号:

TG580.692

郑其涵, 王夏宇, 刘耀庭, 王新昶. 磁流变抛光液流变学特性测试方法及仿真建模[J]. 上海交通大学学报, 2026, 60(8): 1312-1322.

ZHENG Qihan, WANG Xiayu, LIU Yaoting, WANG Xinchang. Method of Rheological Properties Testing and Numerical Simulation of Magnetorheological Polishing Fluid[J]. Journal of Shanghai Jiao Tong University, 2026, 60(8): 1312-1322.

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参数	取值
铁芯外径/mm	35
线圈外径/mm	55
线圈高度/mm	45
线圈匝数	1740
铜线截面直径/mm	0.5
气隙高度/mm	12
励磁电流/A	1

组别	d₁/mm	d₂/mm
#1	25	25
#2	25	30
#3	30	25
#4	30	30
#5	35	25
#6	35	30

本构模型	参数	R²
Power Law	k=0.019 5, n=0.483	0.894
Cross	η₀=0.656 Pa·s, η_∞=0.004 Pa·s, λ=208.435 s, n=0.1	0.969
Carreau	η₀=0.760 Pa·s, η_∞=0.003 Pa·s, λ=779.577 s, n=0.368	0.983

I/A	B/mT	η₀/ (Pa·s)	η_∞/ (Pa·s)	λ/s	n
0	0	0.760	0.003	779.577	0.368
0.3	101	1.366	0.000	415.556	0.335
0.5	170	3.007	0.015	698.040	0.223
1.0	338	8.782	0.063	482.343	0.061
1.5	507	49.536	0.119	382.092	0.034
2.0	678	230.092	0.384	558.928	0.182

组别	$\overline{B}$/mT	流体黏度参数				理论磁场力,F_B/(N·m^-3)
组别	$\overline{B}$/mT	η₀/(Pa·s)	η_∞/(Pa·s)	λ/s	n	F_B_y	F_B_z
#1	0	0.760	0.003	779.577	0.368	0	0
#2	101	1.366	0.000	415.556	0.335	5.87×10⁵	1.17×10⁶
#3	170	3.007	0.015	698.040	0.223	9.78×10⁵	1.96×10⁶
#4	338	8.782	0.063	482.343	0.061	1.96×10⁶	3.91×10⁶
#5	507	49.536	0.119	382.092	0.034	2.93×10⁶	5.87×10⁶
#6	678	230.092	0.384	558.928	0.182	3.91×10⁶	7.83×10⁶