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<p>Integral impellers face significant challenges in conventional polishing, including complex curved surfaces, narrow channels, and poor accessibility, often resulting in scratches, pits, and inconsistent surface quality. To address these issues, this paper proposes a novel immersive fluid-solid coupling polishing method. Unlike traditional mechanical polishing, which causes rigid contact damage, or chemical polishing, which lacks uniform material removal in complex channels, the proposed method uses a rotating hydrodynamic field to drive abrasives for adaptive, micro-scale material removal. A fluid-solid two-phase coupling model is developed to reveal the relationship between process parameters and polishing force, with simulation optimization of rotation speed, abrasive concentration, and particle size. Experiments show that under optimized conditions, surface roughness Ra, Rz, and Rv are reduced to 0.647, 3.217, and 1.844&#xa0;μm, respectively, with scratches and pits effectively eliminated. The polishing mechanism relies on fluid-driven abrasive micro-cutting combined with mild chemical action, achieving both uniform material removal and defect elimination, which differs from pure mechanical or electrochemical mechanisms in previous studies. This work provides a feasible solution for high-quality polishing of integral impellers and similar complex curved component.</p>

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A novel hydrodynamic model for integral impeller confirmed by new immersive fluid-solid coupling process

  • 期刊论文

  • 发表日期：

    2026年7月11日

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  • Jixiang Yi,
  • Longxing Liao,
  • Jian Sun,
  • Rongsen Huang,
  • Fuli Cai

摘要

Integral impellers face significant challenges in conventional polishing, including complex curved surfaces, narrow channels, and poor accessibility, often resulting in scratches, pits, and inconsistent surface quality. To address these issues, this paper proposes a novel immersive fluid-solid coupling polishing method. Unlike traditional mechanical polishing, which causes rigid contact damage, or chemical polishing, which lacks uniform material removal in complex channels, the proposed method uses a rotating hydrodynamic field to drive abrasives for adaptive, micro-scale material removal. A fluid-solid two-phase coupling model is developed to reveal the relationship between process parameters and polishing force, with simulation optimization of rotation speed, abrasive concentration, and particle size. Experiments show that under optimized conditions, surface roughness Ra, Rz, and Rv are reduced to 0.647, 3.217, and 1.844 μm, respectively, with scratches and pits effectively eliminated. The polishing mechanism relies on fluid-driven abrasive micro-cutting combined with mild chemical action, achieving both uniform material removal and defect elimination, which differs from pure mechanical or electrochemical mechanisms in previous studies. This work provides a feasible solution for high-quality polishing of integral impellers and similar complex curved component.