Analysis of vibration from low-rigidity contact in belt grinding of blisk blade

Abstract

A blisk is one of the key parts of an aero-engine, whose surface processing quality directly affects aero-engine performance. Different degrees of vibration occur during the process of new open belt grinding which seriously affect the precision of the dimensions and the surface quality of the entire blade profile. With the aim of addressing this problem, this study constructed a physical model of blisk belt grinding, analysed the low-rigidity characteristics of the grinding system, and researched the vibratory mechanism of the blisk belt grinding system based on a dynamic analysis method. In addition, the factors affecting the stability of the grinding process and the stability conditions of the grinding were considered. Then, the belt grinding process of a blade surface was simulated through a numerical method. The technological parameters were quantified for different conditions of the blisk belt grinding vibration. The optimal combination of process parameters was obtained. Finally, the optimised process parameters were validated experimentally. The research demonstrates that vibration from blisk belt grinding is related to the process parameters as follows, in the order of the greatest influence: the grinding pressure, belt velocity, feed speed, and contact wheel hardness. After optimisation, the cross-sectional profile is 0.031–0.041 mm and the surface roughness is 0.1–0.2 μm; the surface is smoother and has better consistency.

Adaptive CNC machining process optimization of near-net-shaped blade based on machining error data flow control

“…E. Budak et al [16] focused on the milling process of workpieces, and conducted more comprehensive research on cutting force, structural deformation and surface accuracy starting with cutting dynamics. Wu Baohai et al [17][18][19] analyzed the cutting force model and the dynamic characteristics of the blade and Guijian Xiao et al [20] analyzed the vibration model during the abrasive belt polishing process, showing that the rigidity of the weak rigid system affects the machined surface In summary, in order to achieve high-precision machining of near-net-shaped blade, the adaptive CNC machining process should be optimized from the stiffness improvement and machining error control. The structure of this study is arranged as follows.…”

Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy

“…This is because belt grinding operations have a significant role at all stages of manufacturing [ 4 , 5 ]. Therefore, the widespread use of belt grinding operations has determined its high demand [ 6 ] in various industries, such as aerospace [ 7 , 8 ], machinery [ 9 , 10 ], automotive [ 11 , 12 ], rail grinding industry [ 13 , 14 ], etc. However, abrasive belts are often operated ineffectively due to the use of non-rational grinding modes [ 15 ].…”

Microscopic contact pressure and material removal modeling in rail grinding using abrasive belt

“…The abrasive belt, as the most typical coated tool with lots of abrasive grits on its working surface, has developed rapidly over the past few decades. Due to its high flexibility and compliance, 17,18 belt grinding naturally has the mixed effect of grinding and polishing. Hence, it has become an effective machining process in industries, including aerospace, ship, nuclear power and automobile, through kinds of handheld devices, robotics 19–22 and computer numerical control (CNC).…”