Grindability and Surface Integrity of Cast Nickel-based Superalloy in Creep Feed Grinding with Brazed CBN Abrasive Wheels

The technique of creep feed grinding is most suitable for geometrical shaping, and therefore has been expected to improve effectively material removal rate and surface quality of components with complex profile. This article studies experimentally the effects of process parameters (i.e. wheel speed, workpiece speed and depth of cut) on the grindability and surface integrity of cast nickel-based superalloys, i.e. K424, during creep feed grinding with brazed cubic boron nitride (CBN) abrasive wheels. Some important factors, such as grinding force and temperature, specific grinding energy, size stability, surface topography, microhardness and microstructure alteration of the sub-surface, residual stresses, are investigated in detail. The results show that during creep feed grinding with brazed CBN wheels, low grinding temperature at about 100 °C is obtained though the specific grinding energy of nickel-based superalloys is high up to 200-300 J/mm³. A combination of wheel speed 22.5 m/s, workpiece speed 0.1 m/min, depth of cut 0.2 mm accomplishes the straight grooves with the expected dimensional accuracy. Moreover, the compressive residual stresses are formed in the burn-free and crack-free ground surface.     

Al2O3陶瓷蠕动进给超声磨削加工表面质量的试验研究

为探索利用简单形状砂轮对陶瓷材料进行数控展成型面超声磨削,通过对Al2O3陶瓷进行蠕动进给超声磨削和机械磨削对比试验研究,探索各加工参数对磨削表面质量的影响规律.结果表明:超声振动方向与蠕动进给方向平行时可降低表面粗糙度值,而超声振动方向与蠕动进给方向垂直时则不利于改善加工表面质量;在超声磨削条件下,为了提高加工表面质量,应采取较小的磨削深度、较低的进给速度和适当高的磨削速度以及复合进给磨削方式.结合试验结果理论分析了蠕动进给超声磨削和蠕动进给机械磨削加工机理,并根据试验结果选择磨削参数进行了陶瓷叶片型面超声磨削的可行性试验.     

Development of a new high-shear and low-pressure grinding wheel and its grinding characteristics for Inconel718 alloy

Nickel-based alloy has been widely used due to its outstanding mechanical properties. However, Nickel-based alloy is a typical difficult-to-machine material, which is a great constrain for its application in the manufacturing field. To improve the surface quality of the ground workpiece, a new high-shear and low-pressure grinding wheel, with high ratio of tangential grinding force to normal grinding force, was fabricated for the grinding of selective laser melting (SLM) manufactured Inconel718 alloy. The principle of high-shear and low-pressure grinding process was introduced in detail, which was quite different from the conventional grinding process. The fabrication process of the new grinding wheel was illustrated. A serial of experiments with different processing parameters were carried out to investigate the grinding performance of the developed grinding wheel via analyzing surface roughness and surface morphology of the ground workpiece. The optimal processing parameters of high-shear and low-pressure grinding were obtained. The surface roughness of ground workpiece was reduced to 0.232 μm from the initial value of 0.490 μm under the optimal grinding conditions. It was found that the initial scratches on the ground workpiece were almost completely removed after the observations with the metalloscopy and the field-emission scanning electron microscopy (FE-SEM). The capability of the newly developed high-shear and low-pressure grinding wheel was validated.     

TC4钛合金高速外圆磨削表面完整性实验

为充分发挥钛合金的优良性能,以TC4为研究对象进行高速外圆磨削实验,分析外圆磨削工艺参数对工件表面完整性的影响规律。结果表明:工件亚表面未出现变质层;随着砂轮线速度提高,表面质量提高;随着工件转速提高,表面划痕明显;随着磨削深度增加,出现表面烧伤现象,并且磨削深度对表面完整性的影响程度最大;磨削力与磨削温度对表面硬度的影响是正相关的,且磨削力对表面硬度的影响程度较大。因此可以通过选择合理的工艺参数来保证较大的材料去除率与较好的工件表面质量,为TC4钛合金高速外圆磨削提供指导。     

钛合金风扇叶片磨抛加工性能试验研究

针对钛合金风扇叶片磨抛加工中砂轮易磨损、工件表面易烧伤的问题,开展了钛合金材料磨抛加工性试验研究,主要考察砂轮选型、磨抛工艺参数等关键因素对钛合金材料磨抛加工性的影响,并对试验结果进行了分析研究。试验结果表明,在保证工件表面加工质量(R_a0.8μm,表面无烧伤)的前提下,普通磨料砂轮GC46L10V磨抛加工钛合金的材料去除率和磨抛比分别可达5000mm~3/min和2.5,超硬磨料陶瓷结合剂CBN砂轮磨抛加工钛合金的材料去除率和磨抛比分别可达2000mm~3/min和4。基于研究结果,针对钛合金风扇叶片开展了砂带磨抛加工验证试验,工件加工质量良好。     

Analysis of grinding mechanics and improved grinding force model based on randomized grain geometric characteristics

Too high grinding force will lead to a large increase in specific grinding energy, resulting in high temperature in grinding zone, especially for the aerospace difficult cutting metal materials,seriously affecting the surface quality and accuracy. At present, the theoretical models of grinding force are mostly based on the assumption of uniform or simplified morphological characteristics of grains, which is inconsistent with the actual grains. Especially for non-engineering grinding wheel,most g...     

航空发动机叶片叶缘随形磨抛刀路规划

航空发动机叶片是整机核心零件,其制造量占到30%以上。叶片叶缘具有大弯扭复杂曲面、薄壁圆角半径微小渐变、精度要求苛刻等特征,末端工序磨抛的精度和品质直接决定整机的性能与寿命。人工仍然是叶片叶缘磨抛的主要手段,然而粉尘危害健康、经验依赖性强、零件一致性差等不足决定了自动化磨抛是必然趋势。叶片叶缘自动化磨抛多采用砂轮横磨或纵磨的刀路规划方式,存在刀路不连续且分行密集、力控制困难等不足,易造成叶缘局部过切,难以保证圆角轮廓创成。为此,建立了砂带包络叶缘的螺旋进给力控磨抛工艺,提出了面族与复杂曲面高阶切触的随形磨抛路径规划方法,实现了叶片叶缘的宽行高效磨抛。首先对叶缘区域进行横磨刀路规划,然后依照圆弧拟合曲线原理进行高阶切触式包络段再规划,最后进行横纵混合磨抛路径规划实现螺旋式连续进给。针对航空发动机叶片开展仿真和实验验证,结果表明所提出的方法相比于传统的横磨或纵磨方法,可将刀触点减少78.8%,轮廓精度由-0.06~+0.07 mm提高到-0.015~+0.05 mm,表面粗糙度由R_a>3.2 μm提高到0.175 μm,并且有效保证了叶缘轮廓形状,避免了过切现象。     

ELID成形磨削实验研究与表面粗糙度预测

为了探究ELID成型磨削中磨削参数和电解参数对表面粗糙度的影响规律,基于未变形切屑厚度模型,考虑砂轮上磨粒出刃高度的随机性以及ELID磨削中氧化膜的影响,建立了针对ELID磨削的表面粗糙度预测模型。单因素实验研究了ELID成形磨削电源参数对表面粗糙度的影响规律,并探讨了电解电流与氧化膜厚度之间的关系。全因子实验以工件转速、砂轮转速和进给切深为影响因素,研究了磨削参数对表面粗糙度的影响规律,并对预测模型进行了验证。结果表明:磨削参数中,其他条件一定时,表面粗糙度随砂轮转速的增大而减小,随工件转速和切深的增大而增大;同时对于粗糙度的预测误差达到了8.75%,预测模型有效可靠。     

Fretting wear behaviour of machined layer of nickel-based superalloy produced by creep-feed profile grinding

Fretting wear has an adverse impact on the fatigue life of turbine blade roots. The current work is to comparatively investigate the fretting wear behaviour of the nickel-based superalloy surfaces produced by polishing and creep-feed profile grinding, respectively, in terms of surface/subsurface fretting damage, the friction coefficient, wear volume and wear rate. Experimental results show that the granulated tribolayer aggravates the workpiece wear, while the flat compacted tribolayer enhances the wear resistance ability of workpiece, irrespective of whether the workpiece is processed by polishing or grinding. However, the wear behaviors of tribolayers are different. For the polished surface, when the normal load exceeds 100 N, the main defects are crack, rupture, delamination and peeling of workpiece materials; the wear mechanism changes from severe oxidative wear to fatigue wear and abrasive wear when the loads increase from 50 to 180 N. As for the ground surface, the main wear mechanism is abrasive wear. Particularly, the ground surface possesses better wear-resistant ability than the polished surface because the former has the lower values in coefficient friction (0.23), wear volume (0.06 × 10⁶ μm³) and wear rate (0.25 × 10^?16 Pa^?1). Finally, an illustration is given to characterize the evolution of wear debris on such nickel-based superalloy on the ground surface.     

航空燃气涡轮发动机销接转子叶片的减振效果分析

本文介绍关于两种转子叶片振动特性的比较研究。这两种叶片分别是用销钉和纵树形或燕尾形榫头联接到旋转转盘上的，分别用一端铰接一端自由和一端固接一端自由这两种简化的叶片模型来计算两种叶片的振动。首先推导出适用于旋转离心力场中叶片与旋转平面成任意角度振动的传递矩阵，再用推导出的传递矩阵法计算叶片的固有频率和振型。然后根据模态参数计算叶片对气动激励的位移响应，并通过对位移响应的有限差分计算应力响应。两种模型的响应比较表明；销接叶片的最大位移响应要比榫接的稍微大些，但前者的最大应力响应则比后者的小得多。     

单颗磨粒磨削实验及其数值模拟的研究进展

单颗磨粒磨削是研究复杂磨削机理的重要手段,本文从单颗磨粒磨削过程和磨粒形状的角度阐述了磨削基础理论;概述了国内外学者以实验研究单颗磨粒的材料去除、切削力行为;基于数值模拟,探讨了不同工艺参数对单颗磨粒磨削力、磨削温度、工件表面质量的影响规律。最后就这一方向的深入研究工作做了展望。     

缓磨烧伤过程的计算机仿真研究

在关于缓磨时的磨削热 ,接触弧区换热过程以及工件表层非稳态温度场的深入研究的基础上 ,构造了一可用于计算缓磨烧伤前后工件表层温度场畸变历程的数学模型 ,并据此完成了关于缓磨烧伤过程的计算机仿真研究 ,仿真结果与实际吻合良好 ,它率先阐明了缓磨烧伤的热机理并且证明了缓磨烧伤是一具有明显前兆特征的典型渐变过程     

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

航空发动机叶片的型面精度及表面完整性对其疲劳寿命和气流动力性等影响巨大。机器人砂带磨削由于其灵活性好、易于调度、通用性强等特点成为提高叶片表面完整性的有效加工方法之一，但是工业机器人一般仅适用于粗加工，而对于半精加工以及精加工，提高机器人的定位精度是决定加工质量的关键问题。因此，对航空发动机叶片机器人砂带磨削研究现状进行归纳总结，为实现叶片精密磨削提供参考。首先，对叶片机器人砂带磨削系统的组成和结构形式进行了论述，从磨削接触廓形、材料去除规律和表面完整性等方面对砂带磨削机理进行了分析；其次，分别从基于CAD模型、数学模型和人工知识学习三方面总结了叶片机器人砂带磨削轨迹规划方法；然后，对叶片机器人砂带磨削运动控制技术研究进行了介绍，并分析了叶片机器人砂带磨削系统及集成技术；最后，对航空发动机叶片机器人砂带磨削研究现状进行了总结，在此基础上对其发展趋势进行了分析。     

GH4169磨削表面粗糙度影响参数的敏感性研究

通过GH4169高温合金平面切入磨削实验,建立了表面粗糙度的经验公式,分析了表面粗糙度对磨削参数的灵敏度,获得了磨削参数稳定域和非稳定域。结合正交试验法中的极差分析方法获得了不同磨削参数对表面粗糙度的影响曲线,进行了磨削参数区间的优选。研究结果表明:表面粗糙度对磨削深度的变化最为敏感,对工件速度的变化敏感次之,对砂轮速度的变化最不敏感;磨削深度优选范围为0.01～0.015mm,工件速度优选范围为10～15m/min,砂轮速度优选范围为20～30m/s,可控制表面粗糙度在0.7μm以内。为高温合金材料磨削表面粗糙度控制提供理论方法和试验依据。     

Application of novel force control strategies to enhance robotic abrasive belt grinding quality of aero-engine blades

Robotic belt grinding has emerged as a finishing process in recent years for machining components with high surface finish and flexibility.The surface machining consistency, however,is difficult to be guaranteed in such a process.To overcome this problem, a method of hybrid force-position control combined with PI/PD control is proposed to be applied in robotic abrasive belt grinding of complex geometries.Voltage signals are firstly obtained and transformed to force information with signal conditioning methods.Secondly, zero drift and gravity compensation algorithms are presented to calibrate the F/T transducer which is installed on the robot end-effector.Next, a force control strategy combining hybrid force-position control with PI/PD control is introduced to be employed in robotic abrasive belt grinding operations where the force control law is applied to the Z direction of the tool frame and the positon control law is used in the X direction of the tool frame.Then, the accuracy of the F/T transducer and the robotic force control system is analyzed to ensure the stability and reliability of force control in the robotic grinding process.Finally, two typical cases on robotic belt grinding of a test workpiece and an aero-engine blade are conducted to validate the practicality and effectiveness of the force control technology proposed.     

旋转条件下切割SiC 单晶片实验研究

通过旋转条件下切割SiC单晶片,分析了切片表面微观形貌特点,研究了线锯速度、工件进给速度和工件转速对切片表面粗糙度与切向锯切力的影响规律。结果表明:增加工件旋转,切片表面平整光滑,沿线锯运动方向没有明显沟槽及凸起,质量明显得到改善;当转速由0增加到12 r/min时,切片表面粗糙度由1.532μm降到0.513μm;线锯速度和工件旋转速度增大、工件进给速度减小,切向锯切力减小,表面粗糙度减小。当线锯速度和工件旋转速度过大,切向锯切力和表面粗糙度反而会有所增加。     

叶根连接模型的干摩擦微滑移性能

采用在接触面上建立多个接触对以模拟叶根处微滑移的方法和控制变量法，获取稳定状态下二维叶根接触面上摩擦力和相对位移的迟滞回线，分析评估了参考点、网格分配、切向和法向载荷、接触刚度、摩擦因数等参数在微滑移中的影响，从一个新角度考察了叶根干摩擦微滑移的性能。分析结果表明在采用微滑移模型研究叶根连接时，不同参数的选择对其干摩擦性能均有影响。接触单元的数量影响结果的精度，接触面上参考点的选择影响迟滞回线的描述，切向载荷影响迟滞回线中相对位移的大小；法向接触刚度的降低会明显增加相对位移和微滑移区域的大小，切向接触刚度的增加使叶根处更容易进行类似刚体运动的宏观滑移；摩擦因数和正压力的增加使得微滑移区域增加，但两者的影响并不完全一样。同时，从耗散能的角度研究了接触参数的减振效果。      

Modelling of grinding mechanics: A review

Grinding is one of the most widely used material removal methods at the end of many process chains. Grinding force is related to almost all grinding parameters, which has a great influence on material removal rate, dimensional and shape accuracy, surface and subsurface integrity, thermodynamics, dynamics, wheel durability, and machining system deformation. Considering that grinding force is related to almost all grinding parameters, grinding force can be used to detect grinding wheel wear, energy calculation, chatter suppression, force control and grinding process simulation. Accurate prediction of grinding forces is important for optimizing grinding parameters and the structure of grinding machines and fixtures. Although there are substantial research papers on grinding mechanics, a comprehensive review on the modeling of grinding mechanics is still absent from the literature. To fill this gap, this work reviews and introduces theoretical methods and applications of mechanics in grinding from the aspects of modeling principles, limitations and possible future trendencies.     

A trajectory planning method on error compensation of residual height for aero-engine blades of robotic belt grinding

While the traditional trajectory planning methods are used in robotic belt grinding of blades with an uneven machining allowance distribution, it is hard to obtain the preferable profile accuracy and surface quality to meet the high-performance requirements of aero-engine. To solve this problem, a novel trajectory planning method is proposed in this paper by considering the developed interpolation algorithm and the machining allowance threshold. The residual height error obtained from grinding e...     

航空发动机叶片前后缘自由式砂带抛光技术

由于叶片前后缘(LTE)的轮廓形状和表面质量将对航空发动机的气动性能和叶片的疲劳性能产生直接影响,因此为提高前后缘的轮廓度和表面质量,通过对目前航空发动机叶片前后缘抛光所存在的问题进行分析,结合叶片前后缘抛光工艺要求,并基于自由式砂带抛光的工艺特点,提出了叶片前后缘自由式砂带抛光工艺方法;针对该抛光工艺方法,建立其砂带张紧力控制系统,确定了抛光加工中的砂带走刀步长计算公式及抛光轨迹规划方法;最后以某型号叶片的前后缘作为加工对象进行抛光实验研究。检测结果显示:叶片前后缘轮廓度误差小于0.01mm,其表面粗糙度小于0.4μm,证实了该抛光工艺方法对提高叶片前后缘的轮廓度和表面质量的有效性。