航空发动机整体叶盘数控砂带磨削变形行为及其试验研究

针对航空发动机整体叶盘结构复杂,铣削后表面纹理明显,粗糙度和型线精度无法达到设计要求,手工抛光后叶盘表面质量和型面精度难以满足工艺要求的现状,开展整体叶盘数控砂带磨削变形行为及其试验研究。分析整体叶盘数控砂带磨削全型面磨削过程,阐述整体叶盘数控砂带磨削的变形机理,提出一种新型开式数控砂带磨削方法。进行基于ANSYS的磨削变形仿真分析,提出带有压力反馈的磨削压力控制系统方案,实现磨削变形的控制。用磨削试验装置进行整体叶盘精密数控砂带磨削试验,结果表明:整体叶盘数控砂带磨削后,表面粗糙度小于0.4μm,型线精度高于0.05 mm,能够很好地适应叶片变形,实现数控砂带磨削替代手工抛光,提高磨削效率,满足设计要求。

Research on deformation behavior of NC belt grinding of aero-engine blisk and its test

There are obvious textures on milled integrated blisk of aero-engine which has complicated structure to machine so that the roughness and the profile accuracy could not meet the design requirements. In addition, the surface quality and the profile accuracy of manual polished blisk would not satisfy the process requirements as well. To solve these problems, the deformation behavior of numerical control (NC) belt grinding on integrated blisk is investigated and related tests are implemented. A new open NC belt grinding method is proposed and the the full profile grinding process of integrated blisk NC belt grinding is analyzed, the deformation mechanism of which is explained. Based on ANSYS-relied simulation analysis of grinding deformation, a grinding pressure control system with pressure feedback is proposed to control the deformation. The grinding tests of NC belt grinding on integrated blisk are carried out on test equipment. Results indicate that the integrated blisk, after NC belt grinding, has surface roughness less than 0.4 μm and profile accuracy better than 0.05 mm. In conclusion, the developed method could fit the blade shape well, which is to enhance the grinding efficiency and meet the design requirements by replacing manual polishing with NC belt grinding.