航发叶片砂碟磨削接触特性及材料去除机理

doi:10.3901/JME.2023.17.349

机械工程学报 ›› 2023, Vol. 59 ›› Issue (17): 349-360.doi: 10.3901/JME.2023.17.349

• 制造工艺与装备 • 上一篇

扫码分享

航发叶片砂碟磨削接触特性及材料去除机理

段继豪¹, 安佳乐¹, 吴卓繁¹, 淮文博², 高峰¹

1. 西安理工大学陕西省机械制造装备重点实验室西安 710048;
2. 西安理工大学工程训练国家级实验教学示范中心西安 710048

收稿日期:2023-01-11 修回日期:2023-05-08 出版日期:2023-09-05 发布日期:2023-11-16
通讯作者: 段继豪(通信作者),男,1985年出生,博士,讲师。主要研究方向为数控精密磨削加工。E-mail:djh@xaut.edu.cn
作者简介:安佳乐,男,1997年出生,硕士研究生。主要研究方向为精密磨削加工控制。E-mail:568662044@qq.com;吴卓繁,男,2000年出生,硕士研究生。主要研究方向为磨削加工。E-mail:1273120496@qq.com;淮文博,男,1979年出生,博士,副教授。主要研究方向为先进数控加工技术。E-mail:huaiwb@xaut.edu.cn;高峰,男,1969年出生,博士,教授,博士研究生导师。主要研究方向为数控机床设计与制造。E-mail:gf2713@xaut.edu.cn
基金资助:
陕西省重点研发计划（2021ZDLGY09-01）、陕西省自然科学基础研究计划（2023-JC-YB-434、2022JM-240）和陕西省教育厅自然科学专项（19JK0593）资助项目。

Contact Characteristics and Material Removal Mechanism of Abrasive Disc Grinding of Aero-engine Blade

DUAN Jihao¹, AN Jiale¹, WU Zhuofan¹, HUAI Wenbo², GAO Feng¹

1. Key Lab of Manufacturing Equipment of Shaanxi Province, Xi'an University of Technology, Xi'an 710048;
2. National Experimental Demonstration Teaching Center for Engineering Training, Xi'an University of Technology, Xi'an 710048

Received:2023-01-11 Revised:2023-05-08 Online:2023-09-05 Published:2023-11-16

摘要/Abstract

摘要： 航空发动机叶片型面曲率复杂变化、薄壁结构加工刚性弱，使其精密磨削接触状态多变、磨具轨迹规划困难，引起加工表面质量一致性差。为实现叶片磨削工艺优化，基于叶片磨削工艺特点分析，开展叶片砂碟磨削工艺接触特性及材料去除机理研究，利用降维法建立砂碟磨削材料去除率理论模型，通过砂碟磨削接触特性以及材料去除过程仿真研究，揭示了砂碟磨削不同工艺参数对叶片法向接触压力分布、等效法向接触压力、接触面积、接触轮变形及材料去除深度的影响规律，结合砂碟磨削工艺试验，对仿真结果进行验证。研究结果表明，砂碟磨削接触倾角与法向接触压力、接触面积呈负相关，与接触轮最大变形量呈正相关，接触倾角从10°增大到30°，本质使磨具更加锋利，材料去除深度峰值增大约59.78%，有效磨削区域显著降低；随着磨削深度从0.1 mm增大至0.3 mm，法向接触压力、接触面积及接触轮最大变形量均增大，有效磨削区域显著增大，材料去除深度峰值增大1.57倍，达到0.188 mm；接触倾角与磨削深度是影响砂碟磨削材料去除的主要因素，对获得高质量表面并实现磨削工艺控制具有重要的作用。

关键词: 航发叶片, 砂碟磨削, 接触特性, 材料去除率

Abstract: The complex curvature of blade profile and weak machining rigidity of thin-wall structure make it difficult to plan trajectory of grinding tools under the condition of variable contact state, resulting in poor machining consistency accordingly. In order to realize the optimization of blade grinding process, the contact characteristics and material removal mechanism of blade abrasive disc grinding process are studied on the basis of blade grinding characteristics. Firstly, the theoretical model of material removal rate is established based on method of dimensionality reduction. The influence of different process parameters on normal contact pressure distribution, equivalent contact force, contact area, deformation of contact wheel and material removal depth are revealed by means of simulation and experiments. The research results show that there is a negative correlation between inclination angle and normal pressure or contact area, and a positive correlation between inclination angle and maximum deformation of contact wheel. Increasing the inclination angle from 10° to 30° essentially makes abrasive tool sharper. Consequently, the maximum material removal depth increases by about 59.78%, and the effective grinding area is significantly reduced. With the increase of grinding depth from 0.1 mm to 0.3 mm, the normal contact pressure, contact area, contact wheel deformation and effective grinding area increase significantly. And the maximum material removal depth increases by 1.57 times to 0.188 mm. Inclination angle and grinding depth are the main factors affecting material removal rate in abrasive disc grinding, which play an important role in obtaining high quality surface and realizing real-time control of grinding process.

Key words: aero-engine blade, abrasive disc grinding, contact characteristics, material removal rate

中图分类号:

TG580

段继豪, 安佳乐, 吴卓繁, 淮文博, 高峰. 航发叶片砂碟磨削接触特性及材料去除机理[J]. 机械工程学报, 2023, 59(17): 349-360.

DUAN Jihao, AN Jiale, WU Zhuofan, HUAI Wenbo, GAO Feng. Contact Characteristics and Material Removal Mechanism of Abrasive Disc Grinding of Aero-engine Blade[J]. Journal of Mechanical Engineering, 2023, 59(17): 349-360.

参考文献

[1] 朱大虎,徐小虎,蒋诚,等. 复杂叶片机器人磨抛加工工艺技术研究进展[J]. 航空学报,2021,42(10):8-30. ZHU Dahu,XU Xiaohu,JIANG Cheng,et al. Research progress in robotic grinding technology for complex blades[J]. Acta Aeronautica et Astronautica Sinica,2021,42(10):8-30.
[2] ZHU D,FENG X,XU X,et al. Robotic grinding of complex components:A step towards efficient and intelligent machining-challenges,solutions,and applications[J]. Robotics and Computer-Integrated Manufacturing,2020,65:101908.
[3] FU Y,GAO H,WANG X,et al. Machining the integral impeller and blisk of aero-engines:A review of surface finishing and strengthening technologies[J]. Chinese Journal of Mechanical Engineering,2017,30(3):528-543.
[4] 韩强,詹建明,徐克品,等. 大型曲面柔顺抛光材料去除的理论建模及实验研究[J]. 机械科学与技术,2016,35(11):1709-1714. HAN Qiang,ZHAN Jianming,XU Kepin,et al. Modeling and experimental investigation on the material removal in the large surface compliant polishing process[J]. Mechanical Science and Technology for Aerospace Engineering,2016,35(11):1709-1714.
[5] 齐俊德,陈冰. 考虑单磨粒作用的砂带磨削机理模型[J]. 金刚石与磨料磨具工程,2020,40(3):13-20. QI Junde,CHEN Bing. Mechanism model of belt grinding considering single abrasive action[J]. Diamond & Abrasive Engineering,2020,40(3):13-20.
[6] 王涛. 航发叶片机器人磨抛材料去除率建模与刀路规划研究[D]. 武汉:华中科技大学,2020. WANG Tao. Research on the modeling of material removal rate and tool path planning of robot grinding and polishing for aero-engine blades[D]. Wuhan:Huazhong University of Science and Technology,2020.
[7] 刘斐,王伟,王雷,等. 接触轮变形对机器人砂带磨削深度的影响[J]. 机械工程学报,2017,53(5):86-92. LIU Fei,WANG Wei,WANG Lei,et al. Effect of contact wheel's deformation on cutting depth for robotic belt grinding[J]. Journal of Mechanical Engineering,2017,53(5):86-92.
[8] YANG Z,CHU Y,XU X,et al. Prediction and analysis of material removal characteristics for robotic belt grinding based on single spherical abrasive grain model[J]. International Journal of Mechanical Sciences,2021,190:106005.
[9] 黄浩杰. 叶片机器人砂带磨削材料去除率预测研究[D]. 武汉:华中科技大学,2020. HUANG Haojie. Study on prediction of material removal rate in robot abrasive belt grinding of blade[D]. Wuhan:Huazhong University of Science and Technology,2020.
[10] ZHANG M,CHEN T,TAN Y,et al. An adaptive grinding method for precision-cast blades with geometric deviation[J]. The International Journal of Advanced Manufacturing Technology,2020,108:2349-2365.
[11] GAO K,CHEN H,ZHANG X,et al. A novel material removal prediction method based on acoustic sensing and ensemble XGBoost learning algorithm for robotic belt grinding of Inconel 718[J]. The International Journal of Advanced Manufacturing Technology,2019,105(1):217-232.
[12] 黄云,肖贵坚,邹莱. 航空发动机叶片机器人精密砂带磨削研究现状及发展趋势[J]. 航空学报,2019,40(03):53-72. HUANG Yun,XIAO Guijian,ZOU Lai. Current situation and development trend of robot precise belt grinding for areo-engine blade[J]. Acta Aeronautica et Astronautica Sinica,2019,40(03):53-72.
[13] 黄云. 砂带磨削技术的研究现状和发展方向简介[J]. 金刚石与磨料磨具工程,2020,40(3):1-4. HUANG Yun. Brief introduction of research status and development direction of abrasive belt grinding technology[J]. Diamond & Abrasive Engineering,2020,40(3):1-4.
[14] 黄云,李少川,肖贵坚,等. 航空发动机叶片材料及抗疲劳磨削技术现状[J]. 航空材料学报,2021,41(4):17-35. HUANG Yun,LI Shaochuan,XIAO Guijian,et al. Research progress of aero-engine blade materials and anti-fatigue grinding technology[J]. Journal of Aeronautical Materials,2021,41(4):17-35.
[15] 李强,雒建斌. 接触力学与摩擦学的原理及其应用[M]. 北京:清华大学出版社,2019. LI Qiang,LUO Jianbin. Principle and application of contact mechanics and tribology[M]. Beijing:Tsinghua University Press,2019.
[16] POPOV V L,WILLERT E,HEß M. Method of dimensionality reduction in contact mechanics and friction:A user's handbook. III. Viscoelastic contacts[J]. Facta Universitatis,Series:Mechanical Engineering,2018,16(2):99-113.
[17] 钱胜,陆益民,杨咸启,等. 橡胶材料超弹性本构模型选取及参数确定概述[J]. 橡胶科技,2018,16(5):5-10. QIAN Sheng,LU Yimin,YANG Xianqi,et al. Overview of hyperelastic constitutive model selection and parameter determination of rubber materials[J]. Rubber Technology,2018,16(5):5-10.
[18] 张琦,时剑文,索双富,等. 基于Mooney-Rivlin模型和Yeoh模型的橡胶材料有限元分析[J]. 合成橡胶工业,2020,43(6):468-471. ZHANG Qi,SHI Jianwen,SUO Shuangfu,et al. Finite element analysis of rubber materials based on Mooney-Rivlin model and Yeoh model[J]. Synthetic Rubber Industry,2020,43(6):468-471.
[19] HE Z,LI J,LIU Y,et al. Single-grain cutting based modeling of abrasive belt wear in cylindrical grinding[J]. Friction,2020,8(1):208-220.
[20] ARUNACHALAM A P S,IDAPALAPATI S. Material removal analysis for compliant polishing tool using adaptive meshing technique and Archard wear model[J]. Wear,2019,418:140-150.
[21] MOONEY M. A theory of large elastic deformation[J]. Journal of Applied Physics,1940,11(9):582-592.

航发叶片砂碟磨削接触特性及材料去除机理

Contact Characteristics and Material Removal Mechanism of Abrasive Disc Grinding of Aero-engine Blade

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	刘振宇, 张楠, 裘辿, 谭建荣. 基于小样本数据增广的产品服役性能预测方法[J]. 机械工程学报, 2024, 60(6): 11-20.
[2]	段继豪, 周泽伟, 安佳乐, 高峰, 李艳, 淮文博. 基于接触轮柔顺度调控的叶片砂带磨削接触特性研究[J]. 机械工程学报, 2023, 59(15): 354-365.
[3]	张云, 王小东, 陈志同, 朱正清, 叶欢. 面向航发叶片同步抛光的型面聚类分组方法[J]. 机械工程学报, 2022, 58(15): 292-301.
[4]	阎秋生, 廖博涛, 路家斌, 付有志. 集群磁流变变间隙动压平坦化加工试验研究[J]. 机械工程学报, 2021, 57(19): 230-238.
[5]	肖乾, 王丹红, 陈道云, 朱海燕. 考虑齿间滑动影响的高速列车传动齿轮动态接触特性分析[J]. 机械工程学报, 2021, 57(10): 87-94.
[6]	杨沁, 黄辉, 郑生龙. 多线摇摆往复式线锯切割加工运动的理论及试验研究[J]. 机械工程学报, 2020, 56(11): 219-228.
[7]	白宇飞, 王振龙, 赵朝夕, 王玉魁. 放电位置随机分布的电火花线切割加工仿真模型[J]. 机械工程学报, 2019, 55(17): 200-206.
[8]	张卫青, 郭晓东, 张明德. 螺旋锥齿轮端面滚齿切齿计算及接触特性控制[J]. 机械工程学报, 2018, 54(19): 49-57.
[9]	毛聪, 卢继, 梁昶, 张明军, 胡永乐. CBN-WC-10Co复合材料单纤维切削性能[J]. 机械工程学报, 2017, 53(15): 188-200.
[10]	尹韶辉, 王永强, 李叶鹏, 康仁科, 陈逢军, 胡天. 蓝宝石基片的磁流变化学抛光试验研究[J]. 机械工程学报, 2016, 52(5): 80-87.
[11]	计时鸣, 韦伟, 金明生, 曾晰, 王成湖, 陈志龙. 软固结磨粒群内部磨粒拓扑结构对材料去除的影响^*[J]. 机械工程学报, 2016, 52(15): 177-183.
[12]	徐辉, 顾琳, 赵万生, 洪汉, 张发旺, 陈吉朋. 高速电弧放电加工的工艺特性研究[J]. 机械工程学报, 2015, 51(17): 177-183.
[13]	曾晰计时鸣金明生谭大鹏李珏辉曾文韬. 软固结磨粒群气压砂轮的力学特性分析[J]. , 2014, 50(11): 170-177.
[14]	焦黎;吴勇波;郭会茹. 磁场分布对磁性复合流体抛光材料去除率的影响[J]. , 2013, 49(17): 79-84.
[15]	言兰;姜峰;融亦鸣. 基于数值仿真技术的单颗磨粒切削机理[J]. , 2012, 48(11): 172-182.