固结树脂金刚石工具抛光钛合金叶片叶缘工艺

张万一; 徐成宇; 季冬锋; 张天鸿; 朱永伟; 秦凤鸣

doi:10.13394/j.cnki.jgszz.2023.0272

固结树脂金刚石工具抛光钛合金叶片叶缘工艺

doi: 10.13394/j.cnki.jgszz.2023.0272

1.
南京航空航天大学机电学院，南京 210016
2.
郑州磨料磨具磨削研究所有限公司，高性能工具全国重点实验室，郑州 450001

基金项目: 河南省科技攻关计划项目（232102230145）。

详细信息

通讯作者:
朱永伟，男，1967年生，教授、博士生导师。主要研究方向：精密超精密加工、表面工程等。E-mail：meeywzhu@nuaa.edu.cn

中图分类号: TG58; TG74
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出版历程
- 收稿日期: 2023-12-14
- 修回日期: 2024-01-22
- 网络出版日期: 2024-02-21
- 刊出日期: 2024-12-06

Polishing process of titanium alloy blade edges using bonded-resin diamond tools

1.
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
2.
State Key Laboratory for High Performance Tools, Zhengzhou Research Institute for Abrasives and Grinding Co., Ltd., Zhengzhou 450001, China

摘要

摘要: 叶缘作为航空发动机叶片的关键部位，其加工精度直接影响叶片的气动性能，降低叶缘表面粗糙度和轮廓度对延长发动机服役寿命至关重要。为此，设计并开发了固结树脂金刚石弹性抛光轮，基于机器人平台研究钛合金叶片叶缘的抛光工艺。采用正交试验法探索主轴转速、进给速度、加工压力、磨料粒径4个主要工艺参数对叶缘表面粗糙度及轮廓度的影响规律。试验确定的最佳工艺参数组合是：主轴转速为800 r/min，进给速度为6 mm/min，加工压力为4 N，磨料粒径为10～14 μm。在此最佳参数组合下，钛合金叶片叶缘抛光的综合效果较好，其表面形貌得到改善，面型精度提高，表面粗糙度由初始的1.165 μm降为0.213 μm ，轮廓度由初始的0.048 mm降为0.016 mm，可满足使用要求。
- 金刚石弹性抛光轮 /
- 叶缘抛光 /
- 表面粗糙度 /
- 面型精度
Abstract: Objectives: Aero engine blades are important components in engines, and the machining accuracy of the blade edge directly affects the aerodynamic performance of the blade. Improving the surface roughness and the profile accuracy of the blade edge are crucial to improving the service life and the performance of the engine. However, the curvature radius of the blade edge surface varies greatly to even less than 0.05 mm, which puts higher requirements on processing equipment and technology. Therefore, the polishing process of blade edges is studied and a fixed resin diamond elastic polishing wheel adapting to the shape of the blade edge is developed to explore its feasibility on a 6R robot polishing platform when polishing blade edges. Methods: The fixed resin diamond elastic polishing wheel is developed based on the characteristics of small curvature radius and complex surface shape of the blade edge, and a robot polishing platform is built to study the polishing process of Ti alloy blade edges. Firstly, by combining UG secondary development with robot kinematics, the polishing path of the wheel based on the robot platform for polishing blade edges is planned. Secondly, the orthogonal experimental method is used to explore the influences of four main process parameters, namely spindle speed (A), feed rate (B), machining pressure (C), and abrasive particle size (D), on the surface roughness and contour of the blade edge. The optimal combination of process parameters is then obtained. Finally, the titanium alloy blade edge workpiece is polished using the optimal parameter combination, and the surface roughness and the contour of the workpiece after polishing are measured to determine whether the polishing quality of the workpiece meets the requirements for use. Results: The orthogonal experiments are conducted on titanium alloy blade edge polishing using the fixed resin diamond elastic polishing wheel on the 6R robot polishing platform. The experimental data show that: (1) Among the four process parameters A, B, C and D, B has the greatest impact on the blade edge profile with a range R₁ of 0.015. The second greatest influences are from A and C, and the least influence is from D. The optimal combination of process parameters is A₂B₁C₂D₃, that is, the spindle speed is 700 r/min, the feed speed is 6 mm/min, the processing pressure is 4 N, and the abrasive particle size is 10~14 μm. (2) B has the greatest effect on the surface roughness of the blade edge, with its range R₂ being 0.136, which is much higher than that of other parameters. The second greatest influences are from D and A, and the least influence is from C. The optimal combination of process parameters is A₃B₁C₂D₃, that is, the spindle speed is 800 r/min, the feed speed is 6 mm/min, the processing pressure is 4 N, and the abrasive particle size is 10~14 μm. Conclusions: A new type of resin diamond elastic polishing wheel is innovatively designed by combining fixed abrasive technology and elastic polishing technology, which is suitable for the characteristics of large curvature changes and complex surfaces of the blade edge. It is used for orthogonal experiments of blade edge polishing on the 6R robot polishing platform. The experimental results show that the designed and developed elastic polishing wheel is suitable for polishing the edges of titanium alloy blades, and the surface roughness and profile accuracy of the processed edges can meet the requirements for use. At the same time, the optimized process parameter combination for polishing the edge of titanium alloy blades is A₃B₁C₂D₃, which includes a spindle speed of 800 r/min, a feed rate of 6 mm/min, a processing pressure of 4 N, and an abrasive particle size of 10～14 μm. Under these parameters, the overall effect of blade edge polishing is the best, with the surface roughness R_a decreasing from the initial 1.165 μm to 0.213 μm, and the profile decreasing from the initial 0.048 mm to 0.016 mm.
- diamond elastic polishing wheel /
- blade edge polishing /
- surface roughness /
- surface flatness

HTML全文

图 1 发动机叶片叶缘缺陷

Figure 1. Engine blade edge defects

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图 2 固结金刚石弹性抛光轮模型及实物图

Figure 2. Model and physical image of bonded diamond elasticpolishing wheel

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图 3 接触区域示意图

Figure 3. Schematic diagram of contact area

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图 4 固结树脂金刚石抛光轮制作流程

Figure 4. The manufacturing process of resin-bonded diamond polishing wheels

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图 5 抛光试验装置

Figure 5. Polishing test device

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图 6 叶缘理想轮廓提取

Figure 6. Ideal contour extracting of leaf edges

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图 7 未加工叶片叶缘轮廓

Figure 7. Unfinished blade edge contour

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图 8 各因素对叶缘抛光后轮廓度的影响趋势图

Figure 8. Influence trend of various factors on profiles of blade edges after polishing

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图 9 叶缘抛光后轮廓与理想轮廓对比

Figure 9. Comparison between polished blade edge contour and ideal contour

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图 10 各因素对叶缘抛光后表面粗糙度的影响趋势

Figure 10. Influence trend of various factors on surface roughness of polished blade edges

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图 11 叶缘抛光前后表面微观形貌对比

Figure 11. Comparison of surface micromorphology before and after blade edge polishing

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图 12 叶缘抛光前后三维轮廓对比

Figure 12. Comparison of 3D contours before and after blade edge polishing

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表 1 固结树脂金刚石抛光轮组分

Table 1. Components of resin-bonded diamond polishing wheel

成分	质量分数 ω / %
树脂	60.0
金刚石	27.5
固化剂	1.0
成孔剂	10.0
加速剂	0.5
偶联剂	1.0

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表 2 固结树脂金刚石抛光轮制备参数

Table 2. Preparation parameters for resin-bonded diamond polishing wheels

参数	取值
压强 p / MPa	0.5～1.0
固化温度 θ / ℃	65
固化时间 t / s	1500

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表 3 弹性抛光轮抛光叶缘正交试验因素与水平表

Table 3. Factors and levels table for orthogonal experiment of elastic polishing wheel polishing blade edge

水平	主轴转速 n / (r · min⁻¹)	进给速度 v / (mm · min⁻¹)	加工压力 F / N	磨料粒径 d / μm
水平	A	B	C	D
1	600	6	2	50～60
2	700	12	4	20～30
3	800	24	6	10～14

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表 4 钛合金叶片叶缘正交试验轮廓度及极差分析结果

Table 4. Results of orthogonal test on profile and range analysis of titanium alloy blade edges

实验序号	A	B	C	D	轮廓度 δ / mm
1#	600	6	2	50～60	0.022
2#	600	12	4	20～30	0.027
3#	600	24	6	10～14	0.040
4#	700	6	4	10～14	0.014
5#	700	12	6	50～60	0.028
6#	700	24	2	20～30	0.031
7#	800	6	6	20～30	0.020
8#	800	12	2	10～14	0.022
9#	800	24	4	50～60	0.032
k₁	0.030	0.019	0.025	0.027
k₂	0.024	0.026	0.024	0.026
k₃	0.025	0.034	0.029	0.025
极差 R	0.006	0.015	0.005	0.002
因素主次	B>A>C>D

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表 5 钛合金叶片叶缘正交试验表面粗糙度及极差分析结果

Table 5. Surface roughness and range analysis results of orthogonal test on titanium alloy blade edges

实验序号	A	B	C	D	表面粗糙度 R_a / μm
1#	600	6	2	50～60	0.279
2#	600	12	4	20～30	0.316
3#	600	24	6	10～14	0.379
4#	700	6	4	10～14	0.221
5#	700	12	6	50～60	0.358
6#	700	24	2	20～30	0.380
7#	800	6	6	20～30	0.241
8#	800	12	2	10～14	0.263
9#	800	24	4	50～60	0.382
k₁	0.325	0.247	0.310	0.340
k₂	0.322	0.312	0.306	0.315
k₃	0.295	0.383	0.326	0.288
极差 R	0.030	0.136	0.020	0.052
因素主次	B>D>A>C

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