Novel internal finishing of complex, safety critical structures.

复杂结构或功能部件的内表面可能具有相当差的表面光洁度。这对于通过增材层制造（ALM）制成的部件尤其如此。在许多情况下，粗糙度会引发疲劳裂纹，这会破坏部件的可靠性和寿命。在外部部件表面上，可以通过简单的机械抛光进行精加工。对于内表面，抛光更困难，需要更复杂的方法。该项目将评估一种复杂结构内部抛光的新方法，该方法使用一种新型抛光介质，可以从组件外部电磁操纵。波动磁场将用于操纵抛光介质，为组件的所有内表面提供一致的、可预测的抛光。这具有很大的潜力，作为一种新的工艺，实现高度抛光的复杂部件的内部结构与表面光洁度和疲劳性能与传统处理的材料。目前，可靠的、适应性强的内表面光整加工技术是制约复杂内结构在航空航天领域广泛应用的主要技术障碍之一。如果成功，这项新技术将使设计人员能够充分发挥ALM的潜力，为复杂部件的设计和制造提供前所未有的几何自由度，实现迄今为止不可能的细节和功能集成水平。抛光介质的开发和表征2.表面精加工工艺变量的评估3.结构与抛光介质相互作用的电磁特性建模4.通过定制测试台进行技术演示

The internal surfaces of complex structural or functional components can have quite a poor surface finish. This is particularly true of components made by additive layer manufacturing (ALM). In many cases the roughness can initiate fatigue cracks which undermines the reliability and life of a component. On external component surfaces, finishing can be done with simple mechanical polishing. For internal surfaces polishing is more difficult and requires a more complex approach. This project will evaluate a new approach to internal polishing of complex structures which uses a novel polishing media which can be manipulated electromagnetically from the outside of the component. Fluctuating magnetic fields will be used to manipulate the polishing media, providing consistent, predictable polishing to all internal surfaces of a component. This has great potential as a new process for achieving highly polished internal structures of complex components with surface finish and fatigue properties comparable with conventionally processed material. At present a reliable, adaptable internal surface finishing technology is one of the major technical hurdles restricting the widespread use of complex internal structures in aerospace applications. If successful this new technology will enable designers to fully realise the potential of ALM, allowing unparalleled geometric freedom for a design and manufacture of complex components with hitherto impossible levels of detail and functional integration.The project objectives will include:1. Development and characterisation of the polishing media 2. Evaluation of surface finishing process variables3. Modelling electromagnetic characteristics of the structure & polishing media interaction4. Technology demonstration via a custom test rig