向极限挑战的高性能磨削技术发展及其在航空制造领域的应用前景  

Development of High Performance Grinding Processes to Challenge Physical Limitations:Application Prospects in Aeronautical Manufacture Engineering

作　　者：金滩[1] 何训 王其荣 尚振涛[1] JIN Tan;HE Xun;WANG Qirong;SHANG Zhentao(National Engineering Research Center for High Efficiency Grinding,Hunan University,Changsha 410082,China;AECC South Industry Co.,Ltd.,Zhuzhou 412002,China)

机构地区：[1]湖南大学国家高效磨削工程技术研究中心,长沙410082 [2]中国航发南方工业有限公司,株洲412002

出　　处：《航空制造技术》2022年第9期20-33,共14页Aeronautical Manufacturing Technology

基　　金：国防科工局项目(ZQHF–02–02–12)。

摘　　要：磨削加工是精密与超精密零部件加工质量保证的关键环节,在航空制造领域应用广泛。磨削技术目前已发展成为兼具高精度、高质量和高效率的加工技术,在获得极高加工效率的同时,还有利于保证零件加工精度和表面完整性。磨削技术不断突破传统工艺局限,已形成各具特色的高性能磨削工艺技术。高效深切磨削技术采用极高的砂轮线速度,结合大切深和高进给速度,可获得极高的磨削效率,而且加工表面完整性良好,在航空发动机高温合金叶片榫齿的高效成形磨削中显示了良好的效果。快速往复磨削工艺采用直线电机工作台直驱技术,可以实现很高的工作台进给速度,形成有利的传热条件,大部分磨削热可以被磨屑带离磨削区,能够获得较高的磨削效率和良好的表面完整性。快速点磨技术用于大深径比薄壁细长轴的磨削,有利于保证薄壁细长轴的加工精度,提升加工效率。缓进深切磨削技术用于发动机叶片榫齿的深切成形,磨削传热条件复杂,需要进一步开展大切深、复杂曲面接触条件下的磨削传热问题,不同接触条件的粗、精磨工艺设计,以及磨削过程智能监控与优化技术方面的研究。高效深切磨削工艺还可以实现航空铝合金的大去除率深切磨削。高速与超高速磨削技术在高体积分数碳化硅增强铝基复合材料、涡轮盘叶尖飞切磨削等不同领域,具有很好的应用前景。Grinding is widely applied in the aeronautical manufacture industry as an important process technique to guarantee the machining quality of those precision and ultra-precision components.Grinding has been developed into an enabling technology featuring high precision,high machining quality and also high process efficiency.It is capable to achieve high process efficiency with satisfactory machining accuracy and surface integrity.Driven by the application requirements and also the improvements of theoretical understanding,various high-performance grinding techniques have been developed beyond the limits of conventional grinding concepts.By using very high grinding wheel speeds,large depths of cut and also high worktable speeds,HEDG(High efficiency deep grinding)process can achieve extremely high machining efficiency,with good surface integrity on the ground workpiece surface.HEDG process has been successfully applied for the high efficiency grinding of turbine blade roots,showing excellent machining performance.HSSG(High speed stroke grinding)process is based on the linear drive technology for the worktable movement,pushing the feed rate toward an extremely high level,resulting in beneficial heat transfer conditions with most of the heat generated in the grinding zone being removed by the grinding chips,thus capable to achieve high grinding efficiency with good surface integrity.For the precision grinding of thin-walled slender shafts with high ratios of length over diameter,quick-point grinding technique provides the possibility to ensure both machining accuracy and machining efficiency.For the deepcut profile grinding of turbine blade roots using CFG(Creep-feed grinding)process,the heat transfer condition is rather complicated,further research work related with the heat transfer problems under the conditions of deep-cut and complex contact geometry is needed;Further research aspects also include process design method regarding the set up of parameters at different stages including roughing,semi-finishing and fini

关 键 词：高效深切磨削(HEDG) 缓进给磨削(CFG) 快速往复磨削(HSSG) 快速点磨 叶片榫齿 薄壁细长轴 

分 类 号：TG580.6[金属学及工艺—金属切削加工及机床] V261[航空宇航科学与技术—航空宇航制造工程]