Modeling of tool influence function for the abrasive cloth flap wheel and optimization of polishing path spacing and feed rate

In order to use abrasive tools more effectively, it is important to understand their working capability. As a complex, fully-compliant abrasive polishing tool, the tool influence function (TIF) of the abrasive cloth flap wheel (ACFW) has not been studied and modeled. Experimental testing and data analysis was conducted to analyze the variations in the shape of the TIF, maximum material removal depth, material removal volume, and the average offset of the TIF with key process parameters for dry and wet polishing. A TIF experimental model for ACFW polishing was developed using cubic polynomial surface fitting and coefficient regression. Further, based on the principle of curvilinear integration, the cross-sectional profile of single-line polishing with various relative feed angles is accurately simulated, and the influence of the micro-topography in the TIF on the simulation results is discussed. Moreover, a method is proposed for the optimal selection of polishing path spacing and feed rate. Based on the established TIF model and single-line polished section profile calculation, cumulative removal profile simulations and parameter calculation with different polishing line spacing are carried out to select the combination of parameters with the maximum polishing efficiency within the constraints of material removal depth and its uniformity. The results of the validation experiments show that around the optimal parameter combination, the simulated profile follows the same trend as the peak-to-valley (PV) value of the measured profile, and the relative error between the cumulative material removal depth and the target value does not exceed 5%. These research findings establish a foundation and guidance for the more efficient utilization of the ACFW abrasive tool.