Modeling of material removal in dynamic deterministic polishing

In order to realize deterministic material removal as well as achieving the prediction of the material removal in dynamic bonnet polishing process, a theoretical model between material removal and feeding speed of bonnet tool is proposed and experimentally validated. This paper starts with the derivation of the theoretical model, based on the analysis of the dynamic removal process and the differential theory, followed by a two-part verification, in which the simulated results obtained based on the proposed model were compared with those of experiments; it is indicated that, in the dynamic deterministic polishing of one single track (the first part), both the contours and removal depths of simulated results are very close to the experimental, with a maximum error of removal depth to be ∼8.66 %; on the other hand, the outcomes of the dynamic deterministic polishing of whole workpiece surface (the second part) revealed that the contours of three sectional views of simulated and experimental polished areas are similar, and the errors of removal depths on XZ and YZ sectional between the two polished areas are ∼12.5 and ∼12.9 %, respectively. Consequently, in consideration of the dynamic polishing process that is affected by many uncontrolled factors, the differences between the results of the simulations and experiments are reasonable, which validated the engineering application value of the proposed model.