| Citation: | LI Qian, YAO Peng, DENG Hong-xing, FENG Chen-yu, XU Chong-hai, QU Shuo-shuo, YANG Yu-ying, ZHU Hong-tao, HUANG Chuan-zhen. Multi-objective parameter optimization of abrasive water jet polishing for fused silica[J]. Chinese Optics. doi: 10.37188/CO.EN-2025-0006
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As a non-contact ultra-precision machining method, abrasive water jet polishing (AWJP) has significant application in optical elements processing due to its stable tool influence function (TIF), no subsurface damage and strong adaptability to workpiece shapes. In this study, the effects of jet pressure, nozzle diameter and impinging angle on the distribution of pressure, velocity and wall shear stress in the polishing flow field were systematically analyzed by computational fluid dynamics (CFD) simulation. Based on the Box-Behnken experimental design, a response surface regression model was constructed to investigate the influence mechanism of process parameters on material removal rate (MRR) and surface roughness (Ra) of fused silica. And experimental results showed that increasing jet pressure and nozzle diameter significantly improved MRR, consistent with shear stress distribution revealed by CFD simulations. However, increasing jet pressure and impinging angle caused higher Ra values, which was unfavorable for surface quality improvement. Genetic algorithm (GA) was used for multi-objective optimization to establish Pareto solutions, achieving concurrent optimization of polishing efficiency and surface quality. A parameter combination of 2 MPa jet pressure, 0.3 mm nozzle diameter, and 30° impinging angle achieved MRR of 169.05 μm³/s and Ra of 0.50 nm. Experimental verification showed prediction errors of 4.4% (MRR) and 3.8% (Ra), confirming model reliability. This parameter optimization system provides theoretical basis and technical support for ultra-precision polishing of complex curved optical components.
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