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A pneumatic wheel tool with reinforced aramid fiber is presented to finish irregular freeform surface with high hardness. Aramid fiber mainly is selected as a filler to achieve multi-dimension net distribution in polymer. In this case, the wheel can keep the outer abrasive particles more stable and decrease scratch damages of surface in the high-speed machining process. Based on the Halpin-Tsai formula, the orientation coefficient is brought in for the establishment of an elastic modulus prediction model of a fiber-reinforced pneumatic wheel. By ANSYS simulation, rules of stress and strain of pneumatic wheel with different volume ratios of fiber are given. It has been proved out that the fiber-reinforced method can overcome the defect of inner rubber deformation in the contact process. By mixed refining method, pneumatic wheels reinforced by aramid fiber are achieved. Multi-dimension net distribution of aramid fiber–reinforced polymer is observed in a microscopic view. Elastic modulus–predicted model is confirmed by drawing experiments. After that, aramid fiber–reinforced pneumatic wheel machining experiments are carried out. Results show that the fiber-reinforced method can improve surface roughness efficiently in the pneumatic wheel machining process and decrease scratch damages of the surface. [ABSTRACT FROM AUTHOR]

The high hardness and irregular characteristics of laser hardening free-form surface bring many problems into the finishing process. A new autofinishing method based on softness consolidation abrasives (SCA), oriented to laser hardening surface, is brought forward. Abrasives are consolidated on the rubber bonnet by the polymer binder, which have micromovement under the elastic restraint to form stress concentration for cutting. By the modification of coefficients and stress, the material removal model is given by the modified Preston equation. According to a series of simulation and practical experiments, the size of abrasive, hardness of abrasive, and hardness of surface were derived as important factors for the material removal. The empirical results showed that the modified Preston equation is propitious to avoid errors for calculation. Compared with free abrasive methods, it demonstrated that SCA can help to improve at least 13.6 % of efficiency. [ABSTRACT FROM AUTHOR]