Abstract:

Experiments were conducted to reveal the effects of electrode materials with different wear resistance,such as chilled steel electrode, stainless steel electrode, brass electrode and graphite electrode,and ER fluids with different components on the material removal efficiency of common glass. The processing mechanism was also studied. Experimental results indicate that higher efficiency of material removal can be achieved using chilled steel electrode tools and stainless steel electrode tools, thus, the material removal efficiency will enlarge with the increase of the wear resistance of the cone-electrode tool.Furthermore,a greater material removal efficiency can be obtained using the zeolite particle-ER fluid than that using the SiO₂ particles-ER fluid.The reasons are that the wear resistance of cone-electrode material dominates the stability of the working gap between the needle-like tool and workpiece,and that different ER fluids can obviously influence the strength of ER effects,which determines the polishing pressure on the workpiece surface and directly influences the polishing performance of the tiny-grinding wheel.

Key words: electrorheological(ER) effect, rigid-fragile material, polishing, instantaeous tiny-grinding wheel, wear resistance

摘要：

实验研究了基于电流变效应即效微型砂轮研抛加工过程中具有不同耐磨性电极材料（淬火钢电极、不锈钢电极、黄铜电极、石墨电极）、不同组分电流变液对玻璃材料去除率的影响，探讨了其作用机理。结果表明：淬火钢和不锈钢锥状电极的加工效率明显高于黄铜和石墨锥状电极，即采用耐磨性好的工具电极材料具有更好的加工效果；沸石粉电流变液的材料去除率高于二氧化硅电流变液的材料去除率。其作用机理是，锥状工具电极材料的耐磨性决定了工具尖端与工件表面之间的加工间隙的保持性，电流变液组分直接影响了电流变效应的强度，从而影响了电流变效应即效微型砂轮对工件表面的研磨压力，形成了不同的材料去除率。

关键词: 电流变效应, 硬脆材料, 抛光, 即效微型砂轮, 耐磨性