Optimization Study of Shear‐Thickening Polishing Technology in the Passivation Process of Spiral‐Fluted Tap Edge Based on Simulation Analysis

• Published in: Advanced engineering materials 2025-01
• Main Authors: Wang, Xu, Bao, Zhiyuan, Wang, Jiahuan, Lyu, Binghai, Wang, Jinghu, Deng, Qianfa, Zhao, Wenghong, Yuan, Julong
• Format: Article
• Language: English
• ISSN: 1438-1656; 1527-2648
• DOI: 10.1002/adem.202402476

This study examines the effectiveness of shear‐thickening polishing technology in passivating high‐speed steel tap edges through simulation. It analyzes the impact of workpiece speed ( V ), rotary speed ( V ′), and inclination angle ( θ ) on pressure distribution and surface roughness during edge preparation. The simulation shows a peak pressure of 8723.236 Pa at an 80° angle, leading to uniform distribution and reduced surface roughness to 12 nm after 25 min of polishing. A multiresponse optimization method identifies optimal edge preparation conditions at maximum pressure, enhancing edge consistency and minimizing roughness. A mathematical model and universal empirical formula relate edge preparation rate to inclination angle, applicable to various curved edge tools. A regression model explores relationships among inclination angle, rotational speed, and edge blunting radius. The study finds that an inclination angle of 80°, a spin speed of 10 rad min −1 , and a disk speed of 80 rad min −1 can control the edge radius to 30 μm. The research confirms the simulation's reliability and highlights the inclination angle's significant effect on edge radius, providing a theoretical and practical guide for applying shear‐thickening polishing technology in tool edge preparation.