A profile-adaptive compliant polishing tool for aero-engine blade finishing process

Chen, Zhe; Shi, Yaoyao; Lin, Xin; Zhang, Junfeng; Shan, Xiufeng; Zhang, Nan; He, Xiaodong; Li, Hua-lian

doi:10.1007/s00170-019-03477-9

Cited by 13 publications

(5 citation statements)

References 34 publications

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“…The Taguchi method was successfully applied to abrasive and polishing, demonstrating significant improvements in experimental optimization. [ 24–26 ]…”

Section: Methodsmentioning

confidence: 99%

“…The Taguchi method was successfully applied to abrasive and polishing, demonstrating significant improvements in experimental optimization. [24][25][26] This study investigates the primary process parameters affecting the removal rate and surface roughness of quartz glass, namely, polishing speed, polishing gap (distance between the workpiece and the polishing tool), abrasive particle size, and abrasive concentration. Each factor was examined at three equally spaced levels, following the standard L9 (3 4 ) table, where A, B, C, and D represent polishing speed, polishing gap, abrasive particle size, and abrasive concentration, respectively.…”

Section: Optimization Experiments Designmentioning

confidence: 99%

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Parameters Optimization of Active Flexible Tool‐Assisted Shear Thickening Polishing Method for Concave Surface

Chen,

Cai,

Shao

et al. 2024

Adv Eng Mater

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An innovative approach, active flexible tool‐assisted shear thickening polishing (AFT‐STP), is introduced to overcome the limitations of low efficiency involved in shear thickening polishing (STP) process of concave surface. The principle and characteristics of AFT‐STP were presented, accompanied by the design of a flexible tool structure and the creation of an experimental setup. Comparative experiments were executed to confirm the beneficial polishing performances of AFT‐STP on glass workpieces. Utilizing the Taguchi method, experiments were planned and results were assessed via the signal‐to‐noise (S/N) ratio to optimize process parameters. A variance analysis was then employed to ascertain the relative influence of four key parameters—polishing speed, polishing gap, abrasive particle size, and abrasive concentration on the polishing performance of quartz glass in STP. The results indicate that polishing gap had the most pronounced effect on surface roughness (Sa) at 57.5%, followed by abrasive particle concentration at 21.9% and polishing speed at 15.2%, with abrasive particle size exerting the least impact at 5.4%. Concerning material removal rate (MRR), polishing gap exhibited the most substantial influence at 60.4%, followed by polishing speed at 23.9%, and abrasive particle size at 9%, while abrasive concentration had the least impact at 6.7%. The experimental findings yield valuable insights into the polishing process for concave surface components. Under the optimal parameters, a concave quartz glass workpiece with diameter Ø 20 mm and curvature radius 488 mm was polished, the average surface roughness Sa of the five measuring points on the surface decrease from 142.18±8.63 (Avg. ± Std.) nm to 5.34 ±1.16 nm in 45 mins with MRR 57.3 nm/min and the surface defects of the processing area were completely removed, leaving only minor pits. The results show that the AFT‐STP is an effective method for high quality polishing of concave surfaces.This article is protected by copyright. All rights reserved.

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“…The Taguchi method was successfully applied to abrasive and polishing, demonstrating significant improvements in experimental optimization. [ 24–26 ]…”

Section: Methodsmentioning

confidence: 99%

Section: Optimization Experiments Designmentioning

confidence: 99%

Parameters Optimization of Active Flexible Tool‐Assisted Shear Thickening Polishing Method for Concave Surface

Chen,

Cai,

Shao

et al. 2024

Adv Eng Mater

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“…The key technologies of blade processing are thorny problems that the aviation industry urgently needs to overcome. Taking compressor blades as an example, they need to be forged or cast billet, milling, surface grinding, and other processes (such as manual polishing of the blade surface and dynamic balance adjustment of the blade) [2,3] before they can be assembled to the shaft system; Figures 1 and 2 show a milled blade and its surface grinding technology. The machining accuracy of the blade has a great influence on the high-speed rotation accuracy of the shaft system and the performance of the whole machine [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Research on Airflow Cooling Characteristics of Titanium Alloy Engine Blade Surface Machining

Qiu

Zheng

Liu

et al. 2022

Journal of Nanomaterials

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This paper studied the airflow cooling during blade surface processing and explained the applicable occasions of airflow cooling. The flat heat transfer model was used to study the characteristics of the cooling airflow during blade surface processing. The study of the model showed that the cooling coefficient of the airflow was affected by speed and pressure. Furthermore, the generation and strength of the autogenous cooling airflow were closely related to the physical properties of the grinding tool. In terms of processing heat generation, this paper used the Johnson-Cook material constitutive model to calculate the residual heat on the surface of the processed blade, and the surface temperature rise was within a controllable range. For the airflow intensity generated by the high-speed rotation of the tool, the airflow preset method was used to verify whether it meets the processing conditions.

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“…In aero-engine blade precise machining, the super-hard abrasive tool has been used during CNC grinding and polishing of various types of blade and has improved the efficiency of precise machining significantly. 10,11 Inevitably, however, although blades before the grinding or polishing met the design tolerance needs, the clamping position, tool cutting force, cutting heat, residual stress, tool wear, and machining vibration can also lead to machining deformation. 12–14 The deformation will cause the actual blade profile to deviate from the original design and affect the aerodynamic performance of the compressor.…”

Section: Introductionmentioning

confidence: 99%

Research on blade grouping method for array machining

Xiao-dong

Zhang

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Blades are the core component of aero-engines. The complexity of aero-engine blades deformation after multi-axis milling causes poor consistency in batch blades. In turn, the poor consistency of blades affects the aerodynamic performance of an aero-engine. Hence it is critical to ensure the consistency of blades before precise machining. This article proposes a clustering-based blade grouping strategy aiming to improve the consistency of the same group of blades automatically and efficiently. First, the feature vector of the blade and the distance between two blade surfaces are defined. Then the K-medoids clustering algorithm is used to group the blades. According to the maximum allowable distance between the blade surfaces and the Ray-Turi index, the ideal number of clusters, that is the number of groups, is determined. Finally, the clustering center of each cluster is selected as the blade processing model of each group. The experiment for aero-engine blade grouping and machining was performed to demonstrate the effectiveness of the proposed method and the results show that it can improve the consistency of the blades in each group. The geometric contour differences of the blades in the group are not more than 0.02 mm, which can satisfy the requirements of the following precise array machining.

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A profile-adaptive compliant polishing tool for aero-engine blade finishing process

Cited by 13 publications

References 34 publications

Parameters Optimization of Active Flexible Tool‐Assisted Shear Thickening Polishing Method for Concave Surface

Parameters Optimization of Active Flexible Tool‐Assisted Shear Thickening Polishing Method for Concave Surface

Research on Airflow Cooling Characteristics of Titanium Alloy Engine Blade Surface Machining

Research on blade grouping method for array machining

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