Investigation on machining characteristic of pneumatic wheel based on softness consolidation abrasives

In order to improve material removal rate of laser hardening workpiece and also make machining tool suitable for free-form surface, a new method based on the softness consolidation abrasives (SCA) is put forward, which means the abrasives are consolidated on the outer layer of pneumatic wheel to achieve the softness-machining. Binder selecting test shows that acidic silicone is proved to suit for consolidating particles in cutting process. Combined with robot, the machining system has been established. The machining effects of SCA are investigated when it faces with workpiece of different hardness. According to the Preston predicted model, the simulation results of stress and velocity are proven by analysis of average roughness in the contact region. The contrastive machining experimental results show that SCA can supply high cutting stress for material removal and fit for freeform surface’s machining by self-adjustment of flexible body.