A novel polishing method is proposed to increase material removal rates through the acceleration of abrasive movements using micro-jets formed by spontaneous collapses of bubbles due to the cavitation in a special-shaped Venturi tube. The Venturi structure is optimized by numerical simulations. Process-related parameters for the optimal cavitation ratio are investigated for achieving maximum adaptation to polishing flat workpieces. Furthermore, this novel approach enhances processing efficiency by approximately 60% compared to traditional abrasive flow polishing. The processing method that employs cavitation bubbles within a special-shaped Venturi tube to augment the flow of abrasive particles holds significant potential for material polishing applications.

Shear-thickening fluid (STF) is widely applied in various practical engineering fields due to its rheological properties of increased viscosity under load. We investigated the integration of STF with fiber brushes to prepare a novel composite material for polishing applications. The impact of composite material properties is studied in surface finish, specifically roughness and morphology, across flat and uneven surfaces. The effects of the critical variables, including polishing speed, feed depth, and STF concentration, are analyzed through experimentation and simulation. After the STF polishing, the surface roughness of the aluminum alloy sample decreases from 3.125 μm to 0.528 μm, which increases the processing efficiency by 40% compared to Newton polishing slurry. The unique shear-thickening performance of the composite material ensures excellent surface quality and high efficiency in the precision machining of workpieces.

Nowadays, there is a great demand for Zirconia dental ceramics, while the existing low-cost automated polishing methods are quite limited. We propose a novel polishing methodology employing the shear-thickening slurry (STF) comprising starch and SiC abrasive particles. This polishing method enhances viscosity under applied pressure, offering an approach to address the identified challenge. A series of polishing experiments and an in vitro study are conducted to assess the effectiveness of this method compared to manual polishing. The feasibility of the proposed method for polishing dental veneer and crown ceramics is investigated as well. With 2000# SiC-STF slurry, 300 r/min fixture and 120 r/min workpiece, the minimum surface roughness Ra of polished surface can reach 9.5 nm after 30 min. Furthermore, both the novel and manual polishing methods result in samples with comparable flexural strength. Importantly, the innovative use of STF exclusively employs mechanical friction for material removal, circumventing potential chemical erosion. This work can bring a low-cost, efficient, and non-toxic automated polishing method for dental ceramics.