Evaluation and improvement of material removal rate with good surface quality in TC4 blisk blade polishing process

Жен, Чен; Shi, Yaoyao; Lin, Xin

doi:10.1299/jamdsm.2018jamdsm0083

Cited by 12 publications

(8 citation statements)

References 19 publications

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“…The thickness of the blade was measured using a 395-271 electronic digital micrometer (resolution 1 μm, measuring range 0-25 mm), manufactured by Mitutoyo Corporation. The MRR was computed as follows [17]: In this paper, the MRR was indirectly determined by measuring the change in blade thickness. The thickness of the blade was measured using a 395-271 electronic digital micrometer (resolution 1 µm, measuring range 0-25 mm), manufactured by Mitutoyo Corporation.…”

Section: Measurement Methodsmentioning

confidence: 99%

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Optimal Parameter Selection in Robotic Belt Polishing for Aeroengine Blade Based on GRA-RSM Method

et al. 2019

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Due to its flexibility and versatility, robotic belt polishing is one of the most effective processing methods to improve the surface quality of aeroengine blades. Since belt polishing of blades is a material removal process aimed at reducing surface roughness, it is difficult to achieve both minimum surface roughness and maximum material removal rates. In order to solve this problem, this paper proposes an optimization method combining grey correlation analysis (GRA), the Taguchi method, and the response surface method (RSM) for the multiobjective optimization of the process parameters of Ti–6Al–4V aeroengine blade polishing. Meanwhile, the problem of the influence of asymmetry on the polishing process parameters vis-a-vis the optimization goal was solved. Experiments of robotic belt polishing for aeroengine blades were carried out. Based on the results of the principal component analysis, the grey relational grade was established to turn multiobjective optimization into single-objective optimization. A quadratic regression model of Grey correlation grade was developed, and an optimal parameter combination was obtained by the RSM. Finally, verification experiments were performed, and the combination of optimal parameters was obtained as follows: feed rate of 232.09 mm/min, compression amount of 0.08 mm, and belt line speed of 16 m/s, which reduced surface roughness by 6.29% and increased the material removal rate by 16.11%. Comparing the results of GRA-RSM and GRA, the Grey correlation grade increased by 10.96%. In other words, the goal of simultaneously reducing the surface roughness and improving the material removal rate was achieved in robotic belt polishing for aeroengine blades.

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Section: Measurement Methodsmentioning

confidence: 99%

“…The thickness of the blade was measured using a 395-271 electronic digital micrometer (resolution 1 µm, measuring range 0-25 mm), manufactured by Mitutoyo Corporation. The MRR was computed as follows [17]:…”

Section: Measurement Methodsmentioning

confidence: 99%

Optimal Parameter Selection in Robotic Belt Polishing for Aeroengine Blade Based on GRA-RSM Method

et al. 2019

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“…The non-interference movement of the grinding tool was analyzed. Zhao et al (2014) and Chen et al (2018Chen et al ( , 2019 used the method of a "five axis numerical control + flexible polishing head + elastic abrasive tool" to carry out the selfadaptive polishing of the blisk. They developed the flexible polishing spindle and studied the trajectory planning, the in-terference analysis, and the optimization of process parameters during the polishing of the blisk.…”

Section: Introductionmentioning

confidence: 99%

“…The contact force during polishing needs to be controlled (Zhu et al, 2018). Chen et al (2019) presented a novel smart end effector for active contact force control and vibration suppression in robotic polishing of thin-walled blisks. A gravity-compensated force controller was developed to maintain the contact force between the polishing tool and the workpiece to an expected value.…”

Section: Introductionmentioning

confidence: 99%

Design and control of the belt-polishing tool system for the blisk finishing process

et al. 2021

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Abstract. According to the structural characteristics of the blisk, a new adaptive belt tool system for blisk finishing is developed. The pneumatic servo system, which is composed of the cylinder, the servo valve, and the force sensor, is used to control the polishing force. Due to the strong nonlinearity of the pneumatic system, a two-dimensional fuzzy proportion, integral, derivative (PID) controller is developed for the pneumatic force control. The proposed controller adjusts the proportional, integral, and differential parameters of the traditional PID controller in real time through the error and error rate so as to optimize the control performance of the pneumatic system. Compared with the PID control, the steady-state error of the fuzzy PID control is reduced by 0.03 s and the overshoot is reduced by 4 %, which reveals the superiority of the fuzzy PID control algorithm for the nonlinear system. Finally, the experiments of polishing the blisk sample and the real blisk are carried out by the proposed belt tool system. The results show that the polishing process is very stable and the roughness after polishing is less than 0.4 µm, which proves the effectiveness of the proposed new belt tool system and the fuzzy PID controller.

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“…The configuration of the blisk is complex, and a common belt tool system is easy to produce the interference between the cutter and the blade. Zhao et al 13 and Chen et al 14,15 used a method of “five axis numerical control + flexible grinding head + elastic abrasive (emery cloth wheel)” to carry out the self-adaptive polishing of the blisk, and studied the trajectory planning and the process parameter optimization. This method can effectively avoid the phenomena of “over-polishing” and “lacking-polishing.” But the small elastic grinding head is particularly prone to abrade and lead to poor polishing effect.…”

Section: Introductionmentioning

confidence: 99%

Interference analysis and simulation of abrasive belt grinding and polishing of blisk

Zhang

Ding

Cheng

et al. 2014

Advances in Mechanical Engineering

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Blisk is a difficult processing part with complex structure. The polishing quality and accuracy of the blade surface will significantly affect its performance and life. A new abrasive belt system is developed to grind and polish the blade on the blisk. In view of the problem that the abrasive belt is easy to interfere with the adjacent blades in the grinding and polishing process, an algorithm for judging the critical interference state is proposed based on the structural characteristics of the abrasive belt tool system and the actual grinding and polishing process of the blades. On the basis of above, a new algorithm is developed to calculate the range of interference-free wrap angle of the abrasive belt tool system. This paper established a simulation model based on VERICUT software and simulated the process of the blisk polishing. The simulation and experiment results verifies the effectiveness of the algorithm.

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Evaluation and improvement of material removal rate with good surface quality in TC4 blisk blade polishing process

Cited by 12 publications

References 19 publications

Optimal Parameter Selection in Robotic Belt Polishing for Aeroengine Blade Based on GRA-RSM Method

Optimal Parameter Selection in Robotic Belt Polishing for Aeroengine Blade Based on GRA-RSM Method

Design and control of the belt-polishing tool system for the blisk finishing process

Interference analysis and simulation of abrasive belt grinding and polishing of blisk

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