弹性磨具磨抛叶片叶尖圆角工艺研究  

Research on Rounding for Blade Tip Fillet With Elastic Grinding Tool

作　　者：田凤杰[1] 齐子建 张彦智 李论[2] TIAN Fengjie;QI Zijian;ZHANG Yanzhi;LI Lun(Shenyang Ligong University,Shenyang 110159,China;Shenyang Institute of Automation,Chinese Academy of Sciences,Shenyang 110016,China)

机构地区：[1]沈阳理工大学,沈阳110159 [2]中国科学院沈阳自动化研究所,沈阳110016

出　　处：《航空制造技术》2025年第4期76-82,共7页Aeronautical Manufacturing Technology

基　　金：省教育厅重点攻关项目(LJKZZ20220036);中国科学院沈阳自动化研究所基础研究面上项目(2022JK2K09)。

摘　　要：为了实现航空发动机叶片叶尖圆角的自动化磨抛加工,进行了基于弹性磨具的微弧圆角磨抛加工研究,提出了一种可控性良好的叶尖微弧圆角加工方法。以聚酯纤维作为基体材料的弹性磨抛轮,在加工过程中,利用磨抛轮弹性变形的特点使涂附于基体表面的磨料将叶尖顶角磨抛加工成微小半径圆角。基于弹性接触理论与Preston去除理论,建立了磨抛轮与叶尖顶角加工状态下的理论接触模型和材料去除模型,采用Abaqus软件对模型进行了接触区域应力仿真分析,并对去除分布函数进行了仿真。理论证明,弹性磨抛轮与叶尖顶角通过自适应包络接触变形,在加工区域与磨抛轮之间形成“微面触切”,从而实现微小半径圆弧的圆角加工。进行了叶片叶尖顶角的圆角磨抛试验,对实现微小圆弧圆角加工的可行性与可控性进行了验证。结果表明,弹性磨抛轮的自适应包络变形使叶尖顶角加工接触区域形成圆弧状应力分布,涂附于基体上的磨料可以良好地磨抛去除,实现圆角加工。此加工方法实现了叶片叶尖微弧圆角的自动化加工,加工后的叶片尺寸精度高,表面质量一致性良好,表面粗糙度稳定在0.20~0.28μm之间,圆角半径大小变化稳定在16μm范围内。To achieve the automated grinding and polishing of the blade tip fillet in an aero-engine blade,a study on the micro-arc fillet grinding and polishing process based on elastic grinding tools was conducted,and a highly controllable method for machining the micro-arc fillet of the blade tip was proposed.An elastic grinding and polishing wheel with polyester fiber as the base material was employed.By leveraging the characteristic of elastic deformation of the grinding and polishing wheel during the machining process,the abrasive coated on the surface of the base material was used to grind and polish the blade tip apex angle into a micro-radius fillet.Based on the elastic contact theory and the Preston removal theory,the theoretical contact model and material removal model of the grinding and polishing wheel and the blade tip apex angle under the machining state were established.The Abaqus software was utilized to perform a simulation analysis of the stress in the contact region of the model and to simulate the removal distribution function.Theory proves that through the adaptive enveloping contact deformation between the elastic grinding and polishing wheel and the blade tip apex angle,a“micro-surface contact cutting”was formed between the machining region and the grinding and polishing wheel,enabling the machining of a micro-radius arc fillet.The fillet grinding and polishing experiment of the blade tip apex angle was carried out to verify the feasibility and controllability of achieving the micro-arc fillet machining.The results showed that the adaptive enveloping deformation of the elastic grinding and polishing wheel led to an arc-shaped stress distribution in the contact region of the blade tip,and the abrasive coated on the base material could effectively grind and polish to achieve the fillet machining.This machining method effectively realized the automated machining of the micro-arc fillet of the blade tip,with good consistency in dimensional accuracy and surface quality.The roughness Ra was stable betw

关 键 词：弹性磨抛 航空发动机叶片 叶尖 微弧圆角 工艺参数 

分 类 号：TG580.6[金属学及工艺—金属切削加工及机床] V263[航空宇航科学与技术—航空宇航制造工程]