CN113070789B - Polishing method for small and medium-sized aero-engine compressor blades - Google Patents
Polishing method for small and medium-sized aero-engine compressor blades Download PDFInfo
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- CN113070789B CN113070789B CN202110318018.6A CN202110318018A CN113070789B CN 113070789 B CN113070789 B CN 113070789B CN 202110318018 A CN202110318018 A CN 202110318018A CN 113070789 B CN113070789 B CN 113070789B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/14—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding turbine blades, propeller blades or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
Abstract
The invention discloses a polishing method of a compressor blade of a medium and small aircraft engine, which comprises the following steps: the method comprises the following steps of blade polishing area division, wherein a blade profile is divided into a plurality of polishing areas, a polishing track is determined, and a polishing tool is selected; selecting polishing parameters of different areas, and determining different polishing parameters according to the spatial shape, the spatial size and the machining allowance of different areas of the blade; verifying the polishing method, namely verifying the polishing method of the obtained polished blade according to the polishing area, the polishing track and the polishing parameters, and comparing the obtained polished blade with a manually polished blade; determining a polishing method, and correcting the division of the polished area, the polishing track of each area and the polishing parameters of each area by combining a verification test; and polishing the blades of the compressor of the medium and small aircraft engine according to the corrected polishing area division, the polishing tracks of all the areas and the polishing parameters of all the areas.
Description
Technical Field
The invention relates to the field of polishing of engine compressor blades, in particular to a polishing method of small and medium-sized aero-engine compressor blades.
Background
About 1000 ~ 3000 blades are arranged in an aeroengine, and the blade is aeroengine's core part, and the performance and the life-span of engine are directly influenced to the quality of blade quality. Blade polishing is an important process for improving the service life, the fatigue strength and the aerodynamic performance of the blade. The manual polishing of the blade has the defects of unstable quality, poor precision of the processed blade and incapability of meeting the processing requirement of the modern high-performance aeroengine blade, and the polishing is urgently needed to be carried out by adopting a mechanical polishing method. However, the automatic polishing of the small and medium-sized aero-engine compressor blades is difficult due to the reasons of small size, large curvature change and the like, mainly because the air inlet and outlet edges of the blades are small, the shape is very easy to change in the polishing process, so that the shape precision is poor, the shape of the blade root is complex, the accessibility of a common polishing tool is poor, and the polishing of a curved surface with a complex and large-curvature structure is difficult by adopting polishing tools such as abrasive belts and the like, so that the automatic polishing becomes a great problem in the blade processing.
Disclosure of Invention
The invention provides a polishing method for a compressor blade of a medium-small aircraft engine, which aims to solve the technical problems of easy over-polishing, under-polishing and low polishing precision when the medium-small blade with small size, complex and large curvature structure is processed by the existing manual polishing and abrasive belt polishing.
The technical scheme adopted by the invention is as follows:
a polishing method for small and medium-sized aero-engine compressor blades comprises the following steps:
s1, dividing the polishing area of the blade, dividing the profile of the blade into a plurality of polishing areas according to the allowance distribution of the milling process before polishing, the front and rear edges of the blade and the polishing difficulty at the blade root transfer R, determining the polishing track of each polishing area and selecting a polishing tool;
s2, selecting polishing parameters of different areas, and determining different polishing parameters according to the spatial shapes, the spatial sizes and the machining allowance of the different areas of the blade;
s3, verifying the polishing method of the obtained polished blade according to the polishing area, the polishing track and the polishing parameters, and comparing the obtained polished blade with a manual polished blade;
s4, determining a polishing method, and correcting the division of the polished areas, the polishing tracks of all the areas and the polishing parameters of all the areas by combining with a verification test;
and S5, polishing the compressor blades of the medium and small aircraft engines according to the corrected polishing area division, the polishing tracks of the areas and the polishing parameters of the areas.
Further, the blade polishing area in step S1 is divided into six areas, including a polishing area a for the blade basin, a polishing area B for the blade back, a polishing area C for the blade root adapter R, a polishing area D for the air intake and exhaust edge, a polishing area E for the lap joint of the blade body and the air intake and exhaust edge, and a polishing area F for the rabbet flow channel.
Further, the polishing trace of each region in step S1 includes the following steps:
s11, rough polishing of leaf basin and leaf back: carrying out longitudinal feed rough polishing in the polishing area A, wherein a feed track feeds along the profile of the leaf basin, and carrying out longitudinal feed rough polishing in the polishing area B, wherein the feed track feeds along the profile of the leaf back;
s12, rough polishing of the tenon flow passage and the blade root transfer R: performing transverse feed rough polishing in the polishing area C, feeding a feed track from the polishing area A to the polishing area B clockwise, or feeding the feed track from the polishing area B to the polishing area A clockwise to ensure smooth transition and no tool mark at the lap joint of the leaf basin and the blade root and the lap joint of the leaf back and the blade root, and performing transverse feed rough polishing in the polishing area F, wherein the feed track feeds along the profile of the rabbet flow channel;
s13, fine polishing of the lap joint of the blade body and the air inlet and outlet edges: carrying out longitudinal feed finish polishing in the polishing area E, and sequentially processing feed along the profiles at the lap joints of the four blade bodies and the air inlet and outlet edges along a feed track so as to ensure smooth switching of the blade bodies and the front and rear edges;
s14, fine polishing of air inlet and outlet edges: carrying out longitudinal feed fine polishing in the polishing area D, wherein a feed track is fed clockwise from an air inlet edge in transition from the polishing area A to the polishing area B, or fed clockwise from an air exhaust edge in transition from the polishing area B to the polishing area A;
s15, fine polishing of leaf basin and leaf back: carrying out longitudinal feed finish polishing in the polishing area A, wherein a feed track feeds along the profile of the leaf basin, and carrying out longitudinal feed finish polishing in the polishing area B, wherein the feed track feeds along the profile of the leaf back;
s16, fine polishing of the tenon flow channel and the blade root transfer R: and carrying out transverse feed finish polishing on the polishing area C, feeding the feed track clockwise from the polishing area A to the polishing area B or from the polishing area B to the polishing area A, carrying out parallel feed finish polishing on the polishing area F, and feeding the feed track along the molded surface of the tenon flow passage.
Further, a polishing tool for rough polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 400 #; polishing parameters of rough polishing of leaf basin and leaf back: the main shaft of the polishing wheel has the rotating speed of 3550 r/min-3650 r/min, the pre-pressing amount of 0.15 mm-0.25 mm and the feeding amount of 450 mm/min-550 mm/min. Further, a D23r2.5 elastic matrix polishing wheel is adopted as a polishing tool for rough polishing at the transition R of the tenon flow channel and the blade root, and the granularity model of the polishing wheel is 1200 #; polishing parameters of rough polishing of the tenon flow passage and the blade root switching R: the rotation speed of a main shaft of the polishing wheel is 2400 r/min-2600 r/min, the pre-pressing amount is 0.13 mm-0.17 mm, and the feeding amount is 450 mm/min-550 mm/min.
Further, a D23r2.5 elastic matrix polishing wheel is adopted as a polishing tool for finish polishing at the lap joint of the blade body and the air inlet and outlet edges, and the granularity model of the polishing wheel is 2000 #; polishing parameters of finish polishing of the lap joint of the blade body and the air inlet and outlet edges are as follows: the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1700 r/min-1900 r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1400 r/min-1600 r/min, the pre-pressing amount is 0.14 mm-0.16 mm, and the feeding amount is 350 mm/min-450 mm/min.
Further, a D23r2.5 elastic matrix polishing wheel is adopted as a polishing tool for finish polishing of the air inlet and outlet edges, and the granularity model of the polishing wheel is 2000 #; polishing parameters of finish polishing of the air inlet and outlet edges: the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1700 r/min-1900 r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1400 r/min-1600 r/min, the pre-pressing amount is 0.14 mm-0.16 mm, and the feeding amount is 380 mm/min-420 mm/min.
Further, a polishing tool for fine polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, and the grain size model of the polishing wheel is 2000 #; polishing parameters of fine polishing of the leaf basin and the leaf back are as follows: the spindle speed of the polishing wheel is 3800 r/min-4200 r/min, the prepressing amount is 0.2 mm-0.4 mm, and the feeding amount is 650 mm/min-750 mm/min.
Furthermore, a polishing tool for finish polishing at the transition R position of the tenon flow channel and the blade root adopts a D40r2.5 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 1200 #; polishing parameters of finish polishing of the tenon flow passage and the blade root switching R: the rotating speed of the main shaft of the polishing wheel is 2800 r/min-3200 r/min, and the prepressing amount is 0.2 mm-0.4 mm.
Further, the performance parameters of the polished blade compared with the manual polished blade include: surface texture, surface roughness, profile, metallographic structure, frequency, weight, residual stress, high cycle fatigue life.
The invention has the following beneficial effects:
the polishing method of the small and medium-sized aero-engine compressor blade comprises the steps of polishing area division, polishing parameters, polishing tracks and polishing method verification of the blade profile, wherein the blade profile is divided into a plurality of polishing areas, and each area adopts different polishing tools, polishing parameters and polishing tracks, so that the polishing precision is improved, and the blade body profile polishing of the small and medium-sized aero-engine blade can be realized. The polishing method of the small and medium-sized aircraft engine compressor blade can replace the traditional manual polishing at present, the high cycle fatigue life of the blade is prolonged by selecting the polishing tool and the polishing parameters of the adaptive area, the blade profile of the polished blade is obviously improved compared with the manual polishing, the fatigue life is not shorter than that of the manual polishing, and the quality of polishing textures and the like can meet the requirements of engineering application. The method is characterized in that the front edge and the rear edge of the blade of the compressor of the medium and small aero-engine are small in size and large in curvature change of the curved surface, over-polishing and under-polishing are easily generated by manual polishing and abrasive belt polishing, the main reason is that the air inlet and outlet edges of the blade are small, the shape is easily changed in the polishing process, the shape precision is ultra-poor, the shape of the blade root is complex, the accessibility of an abrasive belt polishing tool is poor, the polishing of the curved surface with a complex and large-curvature structure is difficult to perform by adopting polishing tools such as an abrasive belt and the like, the polishing method of the blade of the medium and small aero-engine compressor divides regions according to the structural characteristics of the molded surface of the blade, and different polishing tools, polishing parameters and polishing tracks are adopted according to different regions, so that the high-precision polishing of the medium and small blades is realized.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic view of the leaf basin polishing of the preferred embodiment of the present invention;
FIG. 2 is a schematic view of the polishing of the leaf back of the preferred embodiment of the present invention;
FIG. 3 is a schematic view of the polishing of the root transition R of the preferred embodiment of the present invention;
FIG. 4 is a schematic illustration of a dovetail flow channel finish in accordance with a preferred embodiment of the present invention;
FIG. 5 is a schematic view of the polishing of the lap joint between the blade body and the air inlet and outlet edges of the preferred embodiment of the present invention;
FIG. 6 is a schematic view of the polishing of the air inlet and outlet edges of the preferred embodiment of the present invention;
FIG. 7 is a microscopic view of a leaf of comparative example 1 of the present invention;
FIG. 8 is a leaf microscope photograph of example 1 of the present invention;
FIG. 9 is an untreated blade profile;
FIG. 10 is a comparison of blade profile after treatment by the polishing method of the present invention;
FIG. 11 is a schematic diagram of the residual stress at 4 points of the blade pots of example 1 and comparative example 1 of the present invention; and
fig. 12 is a schematic diagram of the residual stress at 4 points of the blade back of the blade according to example 1 and comparative example 1 of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
FIG. 1 is a schematic view of the leaf basin polishing of the preferred embodiment of the present invention; FIG. 2 is a schematic view of the polishing of the leaf back of the preferred embodiment of the present invention; FIG. 3 is a schematic view of the polishing of the root transition R of the preferred embodiment of the present invention; FIG. 4 is a schematic illustration of a dovetail flow channel finish in accordance with a preferred embodiment of the present invention; FIG. 5 is a schematic view of the polishing of the lap joint between the blade body and the air inlet and outlet edges of the preferred embodiment of the present invention; FIG. 6 is a schematic view of the polishing of the air inlet and outlet edges of the preferred embodiment of the present invention; FIG. 7 is a microscopic view of a leaf of comparative example 1 of the present invention;
FIG. 8 is a leaf microscope photograph of example 1 of the present invention; FIG. 9 is an untreated blade profile; FIG. 10 is a comparison of blade profile after treatment by the polishing method of the present invention; FIG. 11 is a schematic diagram of the residual stress at 4 points of the blade pots of example 1 and comparative example 1 of the present invention; fig. 12 is a schematic diagram of the residual stress at 4 points of the blade back of the blade according to example 1 and comparative example 1 of the present invention.
The polishing method for the compressor blade of the medium and small aircraft engine comprises the following steps:
s1, dividing the polishing area of the blade, dividing the profile of the blade into a plurality of polishing areas according to the allowance distribution of the milling process before polishing, the front and rear edges of the blade and the polishing difficulty at the blade root transfer R, determining the polishing track of each polishing area and selecting a polishing tool;
s2, selecting polishing parameters of different areas, and determining different polishing parameters according to the spatial shapes, the spatial sizes and the machining allowance of the different areas of the blade;
s3, verifying the polishing method of the obtained polished blade according to the polishing area, the polishing track and the polishing parameters, and comparing the obtained polished blade with a manual polished blade;
s4, determining a polishing method, and correcting the division of the polished areas, the polishing tracks of all the areas and the polishing parameters of all the areas by combining with a verification test;
and S5, polishing the compressor blades of the medium and small aircraft engines according to the corrected polishing area division, the polishing tracks of the areas and the polishing parameters of the areas.
The polishing method of the small and medium-sized aero-engine compressor blade comprises the steps of polishing area division, polishing parameters, polishing tracks and polishing method verification of the blade profile, wherein the blade profile is divided into a plurality of polishing areas, and each area adopts different polishing tools, polishing parameters and polishing tracks, so that the polishing precision is improved, and the blade body profile polishing of the small and medium-sized aero-engine blade can be realized. The polishing method of the small and medium-sized aircraft engine compressor blade can replace the traditional manual polishing at present, the high-cycle vibration fatigue life of the blade is prolonged by selecting a polishing tool and polishing parameters of an adaptive area, the blade profile of the polished blade is obviously improved compared with the manual polishing, the fatigue life is not shorter than that of the manual polishing, and the quality such as polishing texture and the like can meet the requirements of engineering application. The method is characterized in that the front edge and the rear edge of the blade of the compressor of the medium and small aero-engine are small in size and large in curvature change of the curved surface, over-polishing and under-polishing are easily generated by manual polishing and abrasive belt polishing, the main reason is that the air inlet and outlet edges of the blade are small, the shape is easily changed in the polishing process, the shape precision is ultra-poor, the shape of the blade root is complex, the accessibility of an abrasive belt polishing tool is poor, the polishing of the curved surface with a complex and large-curvature structure is difficult to perform by adopting polishing tools such as an abrasive belt and the like, the polishing method of the blade of the medium and small aero-engine compressor divides regions according to the structural characteristics of the molded surface of the blade, and different polishing tools, polishing parameters and polishing tracks are adopted according to different regions, so that the high-precision polishing of the medium and small blades is realized.
In this embodiment, the blade polishing area in step S1 is divided into six areas, including a polishing area a for the blade basin, a polishing area B for the blade back, a polishing area C for the blade root adapter R, a polishing area D for the air intake and exhaust edge, a polishing area E for the lap joint of the blade body and the air intake and exhaust edge, and a polishing area F for the rabbet flow channel. According to the structural characteristics and the processing difficulty of the blade profile of the blade, the blade polishing area is divided into six areas.
As shown in fig. 1, 2, 3, 4, 5 and 6, in the present embodiment, the polishing track of each area in step S1 includes the following steps:
s11, rough polishing of leaf basin and leaf back: carrying out longitudinal feed rough polishing in the polishing area A, wherein a feed track feeds along the profile of the leaf basin, and carrying out longitudinal feed rough polishing in the polishing area B, wherein the feed track feeds along the profile of the leaf back;
s12, rough polishing of the tenon flow passage and the blade root transfer R: performing transverse feed rough polishing in the polishing area C, feeding a feed track from the polishing area A to the polishing area B clockwise, or feeding the feed track from the polishing area B to the polishing area A clockwise to ensure smooth transition of the lap joint of the blade back and the blade root without tool marks, performing upper and lower feed rough polishing in the polishing area F, and feeding the feed track along the profile of the tenon flow channel;
s13, fine polishing of the lap joint of the blade body and the air inlet and outlet edges: carrying out longitudinal feed finish polishing in the polishing area E, and sequentially processing feed along the profiles at the lap joints of the four blade bodies and the air inlet and outlet edges along a feed track so as to ensure smooth switching of the blade bodies and the front and rear edges;
s14, fine polishing of air inlet and outlet edges: carrying out longitudinal feed fine polishing in the polishing area D, wherein a feed track is fed clockwise from an air inlet edge in transition from the polishing area A to the polishing area B, or fed clockwise from an air exhaust edge in transition from the polishing area B to the polishing area A;
s15, fine polishing of leaf basin and leaf back: carrying out longitudinal feed finish polishing in the polishing area A, wherein a feed track feeds along the profile of the leaf basin, and carrying out parallel feed finish polishing in the polishing area B, wherein the feed track feeds along the profile of the leaf back;
s16, fine polishing of the tenon flow channel and the blade root transfer R: and carrying out transverse feed finish polishing in the polishing area C, feeding the feed track from the polishing area A to the polishing area B clockwise, or feeding the feed track from the polishing area B to the polishing area A clockwise, carrying out parallel feed finish polishing in the polishing area F, and feeding the feed track along the profile of the tenon flow passage.
The polishing track of the blade is determined aiming at the complexity of the molded surface of the blade of the compressor of the medium and small aircraft engine, and the polishing sequence of the blade is further determined, and the polishing sequence of the blade can be connected in order to obtain better polishing quality. Through process analysis and practice exploration, the rough polishing and the fine polishing of the leaf basin and the leaf back are determined, the molded surface area of the leaf basin and the leaf back is large, and the polishing efficiency and the polishing quality can be remarkably improved by adopting the twice polishing treatment. The tenon flow passage and the blade root transfer R are also subjected to rough polishing and then finish polishing to form a rough edge plate and a rough blade root so as to form a smooth molded surface. The blade body and the fine polishing of the lap joint of the air inlet and outlet edges, the fine polishing of the air inlet and outlet edges, and the profiles near the air inlet and outlet edges need to be subjected to corner turning during cutter machining, so that traces can be generated, and the profiles need to be polished separately.
In this embodiment, the polishing tool for rough polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, and the grain size of the polishing wheel is 400 #. Polishing parameters of rough polishing of leaf basin and leaf back: the main shaft of the polishing wheel has the rotating speed of 3550 r/min-3650 r/min, the pre-pressing amount of 0.15 mm-0.25 mm and the feeding amount of 450 mm/min-550 mm/min. Preferably, the polishing parameters of the rough polishing of the leaf basin and the leaf back are as follows: the spindle speed of the polishing wheel is 3600r/min, the pre-pressing amount is 0.2mm, the feeding amount is 500mm/min, the row width of the blade back is 1.266mm, and the row width of the blade basin is 1.296 mm. Rough polishing of the leaf basin and the leaf back, basic removal of milling knife lines and preparation for fine polishing. The polishing parameters are obtained through preliminary experiments in the early stage, so that the obtained fatigue life of the blade, the quality of polishing textures and the like can meet the requirements of engineering application, and particularly in the aspect of the high cycle fatigue life of the blade, the optimized polishing parameters enable the fatigue life to be improved by about 2 times of the existing fatigue life. The line width refers to the width between parallel tool paths, and can be properly adjusted according to the polishing efficiency and the polished surface quality.
In this embodiment, the polishing tool for rough polishing at the transition R of the tenon flow channel and the blade root adopts a D23r2.5 elastic matrix polishing wheel, and the grain size of the polishing wheel is 1200 #. Polishing parameters of rough polishing of the tenon flow passage and the blade root switching R: the rotation speed of a main shaft of the polishing wheel is 2400 r/min-2600 r/min, the pre-pressing amount is 0.13 mm-0.17 mm, and the feeding amount is 450 mm/min-550 mm/min. Preferably, the spindle of the polishing wheel has a rotation speed of 2500r/min, a pre-pressing amount of 0.15mm and a feeding amount of 500 mm/min. The row width of the root part of the leaf basin is 0.41mm, the row width of the root part of the leaf back is 0.8mm, the row width of the root part of the leaf basin is 0.35mm, the row width of the root part of the leaf back is 0.495mm, the row width of the transition edge of the leaf basin is 0.2mm, and the row width of the transition edge of the leaf back is 0.2 mm. The rough polishing of the tenon flow channel and the blade root adapting R removes the knife lines of the blade root, the blade root adapting R is in smooth transition and has no knife lines, and the rotating speed of the spindle of the polishing wheel needs to be strictly controlled in the process.
In this embodiment, the polishing tool for finish polishing at the lap joint of the blade body and the air inlet and outlet edges adopts a D23r2.5 elastic base polishing wheel with the granularity model of 2000 #. Polishing parameters of finish polishing of the lap joint of the blade body and the air inlet and outlet edges are as follows: the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1700 r/min-1900 r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1400 r/min-1600 r/min, the pre-pressing amount is 0.14 mm-0.16 mm, and the feeding amount is 350 mm/min-450 mm/min. Preferably, the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1800r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1500r/min, the pre-pressing amount is 0.15mm, and the feeding amount is 400 mm/min. The line width was 0.053 mm. The fine polishing of the lap joint of the blade body and the air inlet and outlet edges can uniformly remove machining allowance, so that the blade body is smoothly connected with the front edge and the rear edge in a switching way.
In this embodiment, the polishing tool for finish polishing of the air inlet and outlet edges adopts a D23r2.5 elastic base polishing wheel, and the grain size of the polishing wheel is 2000 #. Polishing parameters of finish polishing of the air inlet and outlet edges: the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1700 r/min-1900 r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1400 r/min-1600 r/min, the pre-pressing amount is 0.14 mm-0.16 mm, and the feeding amount is 380 mm/min-420 mm/min. Preferably, the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1800r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1500r/min, the pre-pressing amount is 0.15mm, and the feeding amount is 400 mm/min. The line width was 0.053 mm. The finish polishing can uniformly remove the machining allowance, and the requirement of the roughness of the molded surface is met.
In this embodiment, the polishing tool for finish polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, and the grain size of the polishing wheel is 2000 #. Polishing parameters of fine polishing of the leaf basin and the leaf back are as follows: the spindle speed of the polishing wheel is 3800 r/min-4200 r/min, the prepressing amount is 0.2 mm-0.4 mm, and the feeding amount is 650 mm/min-750 mm/min. Preferably, the spindle speed of the polishing wheel is 4000r/min, the pre-pressing amount is 0.3mm, the feeding amount is 700mm/min, the row width of the blade back is 0.32mm, and the row width of the blade basin is 0.32 mm. The polishing tracks are more dense by selecting different polishing wheels.
In this embodiment, the polishing tool for finish polishing at the transition R of the tenon flow channel and the blade root adopts a 40r2.5 elastic matrix polishing wheel, and the grain size of the polishing wheel is 1200 #. Polishing parameters of finish polishing of the tenon flow passage and the blade root switching R: the spindle speed of the polishing wheel is 2800 r/min-3200 r/min, the prepressing amount is 0.2 mm-0.4 mm, and the feeding amount is 450 mm/min-550 mm/min. Preferably, the spindle of the polishing wheel has a rotating speed of 3000r/min, a pre-pressing amount of 0.3mm and a feeding amount of 500 mm/min. The line width was 0.6 mm.
In this embodiment, the performance parameters of the comparison between the polished blade and the manual polished blade include: surface texture, surface roughness, profile, metallographic structure, frequency, weight, residual stress, high cycle fatigue life. The surface texture, the metallographic structure, the surface roughness, the profile degree of the blade profile, the surface stress, the high cycle fatigue life and the like of the polished blade all meet relevant requirements.
Examples
Example 1
The polishing method of the small and medium-sized aero-engine compressor blade comprises the following steps:
s1, dividing a blade polishing area into six areas according to allowance distribution of a numerical milling process before polishing, polishing difficulties of the front edge and the rear edge of the blade and the blade root transfer R, wherein the six areas comprise a polishing area A of a blade basin, a polishing area B of a blade back, a polishing area C of a blade root transfer R, a polishing area D of an air inlet and exhaust edge, a polishing area E of a lap joint of a blade body and the air inlet and exhaust edge, and a polishing area F of a tenon flow passage, and determining the polishing track of each polishing area, the method comprises the following steps:
s11, rough polishing of leaf basin and leaf back: carrying out longitudinal feed rough polishing in the polishing area A, wherein a feed track feeds along the profile of the leaf basin, and carrying out longitudinal feed rough polishing in the polishing area B, wherein the feed track feeds along the profile of the leaf back;
s12, rough polishing of the tenon flow passage and the blade root transfer R: performing transverse feed rough polishing in the polishing area C, feeding a feed track from the polishing area A to the polishing area B clockwise, or feeding the feed track from the polishing area B to the polishing area A clockwise to ensure smooth transition of the lap joint of the blade back and the blade root without tool marks, performing upper and lower feed rough polishing in the polishing area F, and feeding the feed track along the profile of the tenon flow channel;
s13, fine polishing of the lap joint of the blade body and the air inlet and outlet edges: carrying out longitudinal feed finish polishing in the polishing area E, and sequentially processing feed along the profiles at the lap joints of the four blade bodies and the air inlet and outlet edges along a feed track so as to ensure smooth switching of the blade bodies and the front and rear edges;
s14, fine polishing of air inlet and outlet edges: carrying out longitudinal feed fine polishing in the polishing area D, wherein a feed track is fed clockwise from an air inlet edge in transition from the polishing area A to the polishing area B, or fed clockwise from an air exhaust edge in transition from the polishing area B to the polishing area A;
s15, fine polishing of leaf basin and leaf back: carrying out longitudinal feed finish polishing in the polishing area A, wherein a feed track feeds along the profile of the leaf basin, and carrying out parallel feed finish polishing in the polishing area B, wherein the feed track feeds along the profile of the leaf back;
s16, fine polishing of the tenon flow channel and the blade root transfer R: and carrying out transverse feed finish polishing in the polishing area C, feeding the feed track from the polishing area A to the polishing area B clockwise, or feeding the feed track from the polishing area B to the polishing area A clockwise, carrying out parallel feed finish polishing in the polishing area F, and feeding the feed track along the profile of the tenon flow passage.
S2, selecting polishing parameters of different areas, and determining different polishing parameters according to the spatial shapes, the spatial sizes and the machining allowance of the different areas of the blade;
the polishing tool for rough polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, the granularity model of the polishing wheel is 400#, and the polishing parameters of the rough polishing of the leaf basin and the leaf back are as follows: the rotating speed of a main shaft of the polishing wheel is 3600r/min, the pre-pressing amount is 0.2mm, the feeding amount is 500mm/min, the row width of a leaf back is 1.266mm, and the row width of a leaf basin is 1.296 mm;
the polishing tool for rough polishing of the tenon flow channel and the blade root adapting R adopts a D23r2.5 elastic matrix polishing wheel, the granularity model of the polishing wheel is 1200#, and the polishing parameters for rough polishing of the tenon flow channel and the blade root adapting R are as follows: the main shaft rotating speed of the polishing wheel is 2500r/min, the prepressing amount is 0.15mm, the feeding amount is 500mm/min, the row width of the root part of a leaf basin is 0.41mm, the row width of the root part of a leaf back is 0.8mm, the row width of the root part of the leaf basin is 0.35mm, the row width of the root part of the leaf back is 0.495mm, the row width of a transition edge of the leaf basin is 0.2mm, and the row width of the transition edge of the leaf back is 0.2 mm;
the polishing tool for finish polishing of the lap joint of the blade body and the air inlet and outlet edge adopts a D23r2.5 elastic base polishing wheel, the granularity model of the polishing wheel is 2000#, and the polishing parameters of finish polishing of the lap joint of the blade body and the air inlet and outlet edge are as follows: the rotating speed of the main shaft of the polishing wheel at the air inlet side is 1800r/min, the rotating speed of the main shaft of the polishing wheel at the air outlet side is 1500r/min, the pre-pressing amount is 0.15mm, and the feeding amount is 400 mm/min.
The line width is 0.053 mm;
the polishing tool for the finish polishing of the air inlet and outlet edges adopts a D23r2.5 elastic base polishing wheel, the granularity model of the polishing wheel is 2000#, and the polishing parameters of the finish polishing of the air inlet and outlet edges are as follows: the rotating speed of the main shaft of the polishing wheel at the air inlet side is 1800r/min, the rotating speed of the main shaft of the polishing wheel at the air outlet side is 1500r/min, the pre-pressing amount is 0.15mm, the feeding amount is 400mm/min, and the line width is 0.053 mm.
The polishing tool for the fine polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, the granularity model of the polishing wheel is 2000#, and the polishing parameters of the fine polishing of the leaf basin and the leaf back are as follows: the main shaft rotating speed of the polishing wheel is 4000r/min, the pre-pressing amount is 0.3mm, the feeding amount is 700mm/min, the row width of the blade back is 0.32mm, and the row width of the blade basin is 0.32 mm.
The polishing tool for the finish polishing of the tenon flow channel and the blade root switching R adopts a D40r2.5 elastic matrix polishing wheel, the granularity model of the polishing wheel is 1200#, and the polishing parameters for the finish polishing of the tenon flow channel and the blade root switching R are as follows: the spindle speed of the polishing wheel is 3000r/min, the prepressing amount is 0.3mm, the feeding amount is 500mm/min, and the line width is 0.6 mm.
S3, verifying the polishing method of the obtained polished blade according to the polishing area, the polishing track and the polishing parameters, and comparing the obtained polished blade with a manual polished blade;
s4, determining a polishing method, and correcting the division of the polished areas, the polishing tracks of all the areas and the polishing parameters of all the areas by combining with a verification test;
and S5, polishing the compressor blades of the medium and small aircraft engines according to the corrected polishing area division, the polishing tracks of the areas and the polishing parameters of the areas.
Comparative example 1
A manual polishing method is adopted.
And (3) comparing the performance test of the blade obtained by the polishing method of the compressor blade of the medium and small aircraft engine in the example 1 with the performance test of the blade obtained by manual polishing in the comparative example 1.
(1) Surface texture detection
Through the detection of a super-depth-of-field three-dimensional video microscope, the results are as shown in the blade surface appearances of fig. 7 and fig. 8, the area with good manual polishing of fig. 7 is very close to the polishing surface of the polishing method of the small and medium aero-engine compressor blade of fig. 8, the two can completely replace each other in roughness and surface texture, and the phenomenon of under-polishing or missing polishing is avoided.
In addition, through observation, the blade obtained by the polishing method of the invention has more uniform texture and consistent depth, the whole outer surface is completely the same, and the phenomena of missing polishing, scratch, crossed and disordered texture, discontinuous bump and the like inevitably exist in manual polishing.
(2) Roughness measurement
The thickness of the blade obtained by the polishing method of the compressor blade of the medium and small aircraft engine in the embodiment 1 and the thickness of the blade basin and the blade back of the blade obtained by manual polishing in the comparative example 1 are respectively measured by selecting 6 same positions.
TABLE 1 roughness values
As can be seen from the data in Table 1, the roughness values are satisfactory, with the lowest roughness value of 0.12 μm for the blade of example 1, all values being below 0.2 μm.
(3) Leaf profile detection
The polished blade of example 1 was examined for cross-section by a coordinate measuring machine, i, iii, and iv were selected as the upper, middle, and lower three cross-sections of the blade, and the untreated blade and the blade treated in example 1 were compared.
The surface profile of the blade obtained by the polishing method of the small and medium-sized aircraft engine compressor blade in the embodiment 1 is obviously improved, as can be seen from fig. 9, the untreated blade line profile is 0.02 mm-0.11 mm, as can be seen from fig. 10, the processed blade line profile is-0.05 mm-0 mm, the profile is stably controlled in a tolerance zone, and the profile precision is improved by about 2 times.
(4) Frequency and weight detection
And (3) comparing the performance test of the blade obtained by the polishing method of the compressor blade of the medium and small aircraft engine in the example 1 with the performance test of the blade obtained by manual polishing in the comparative example 1.
Randomly selecting 10 blades obtained by the polishing method of the compressor blade of the medium and small aircraft engine in the example 1, wherein the blade is numbered as 16-15-128, 16-15-115, 16-15-129, 16-15-123, 16-15-111, 16-15-175, 16-15-124, 16-15-117, 16-15-148 and 16-15-121, also randomly selecting 10 blades obtained by manual polishing in the comparative example 1, and the blade is numbered as 17-12-104, 17-12-80, 17-12-84, 17-12-74, 17-12-20, 17-12-18, 17-12-102, 17-12-48, 17-12-88 and 17-12-86, frequency and weight measurements were made and data statistics are shown in the table below.
TABLE 2 frequency and weight
As can be seen from table 2, the blade of example 1 and the blade of comparative example 1 have smaller frequency and weight difference, but the blade of example 1 has smaller fluctuation value range and is more stable, and the frequency: the fluctuation value of comparative example 1 was 39Hz, and the fluctuation value of example 1 was 24 Hz; weight: the differences between comparative example 1 and example 1 were all 0.39 g.
(5) Residual stress detection
Randomly selecting 5 blades of example 1, wherein the numbers are 16-15-121, 16-15-123, 16-15-124, 16-15-148 and 16-15-175, randomly selecting 5 blades of comparative example 1, wherein the numbers are 17-12-80, 17-12-86, 17-12-88, 17-12-102 and 17-12-104, and respectively selecting 1 point, 2 points, 3 points and 4 points of a basin of the blade and 5 points, 6 points, 7 points and 8 points of a blade back to carry out residual stress test.
The test results are shown in fig. 11 and fig. 12, the residual stress types of the comparative example 1 and the example 1 are compressive stresses, the compressive stress value at the same position point fluctuates within a certain range, the compressive stresses can reduce the fatigue crack propagation rate, and the fatigue service life of the part is increased.
(6) High cycle fatigue life detection
Randomly selecting 11 blades of example 1, wherein the numbers are 19-2-36, 19-2-59, 19-2-44, 19-2-22, 19-2-46, 19-2-34, 19-2-40, 19-2-7, 19-2-21 and 19-2-39, randomly selecting 12 blades of comparative example 1, the numbers of the parts are 18-3-108, 18-3-99, 18-3-104, 18-3-102, 18-3-100, 18-3-103, 18-3-106, 18-3-101, 18-3-110, 18-3-109, 18-3-105 and 18-3-107, and the high-cycle vibration fatigue test is carried out. The test is carried out at room temperature, the blade tenon is fixed, the blade body is free, the test is carried out under a bending vibration mode, the test is carried out on an A777 electromagnetic vibration table, the maximum sine thrust is 29kN, the bearing capacity is 200kg, and the effective frequency range is 5 Hz-3000 Hz. The test results are detailed in table 3 below.
TABLE 3 high cycle fatigue life of the blades of example 1
Blade of example 1: the log life averages are: 5.748736, converting into: 560707.02.
TABLE 4 high cycle fatigue life of the blade of comparative example 1
Blade of comparative example 1: the log life averages are: 5.4717, converting into: 296278.40. from this, it is understood that the high cycle fatigue life of the blade of example 1 is 1.9 times that of the blade of comparative example.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (8)
1. A polishing method for small and medium-sized aero-engine compressor blades is characterized by comprising the following steps:
s1, blade polishing area division, wherein the blade polishing area division in the step S1 comprises a blade basin as a polishing area A, a blade back as a polishing area B, a blade root transfer R as a polishing area C, an air inlet and outlet edge as a polishing area D, a blade body and air inlet and outlet edge lap joint as a polishing area E, a tenon flow passage as a polishing area F, the blade profile is divided into a plurality of polishing areas according to the margin distribution of a plurality of milling processes before polishing, the front and rear edges of the blade and the polishing difficulty of the blade root transfer R, the polishing track of each polishing area is determined, and a polishing tool is selected,
the polishing trace of each region in step S1 includes the steps of:
s11, rough polishing of leaf basin and leaf back: carrying out longitudinal feed rough polishing in a polishing area A, wherein a feed track feeds along the leaf basin profile, and carrying out longitudinal feed rough polishing in a polishing area B, wherein the feed track feeds along the leaf back profile;
s12, rough polishing of the tenon flow passage and the blade root transfer R: performing transverse feed rough polishing in the polishing area C, feeding a feed track clockwise from the polishing area A to the polishing area B, or feeding the feed track clockwise from the polishing area B to the polishing area A to ensure smooth transition and no tool mark at the lap joint of the blade basin and the blade root and the lap joint of the blade back and the blade root, and performing transverse feed rough polishing in the polishing area F, wherein the feed track feeds along the profile of the rabbet flow channel;
s13, fine polishing of the lap joint of the blade body and the air inlet and outlet edges: carrying out longitudinal feed finish polishing in the polishing area E, and sequentially processing feed along the profiles at the lap joints of the four blade bodies and the air inlet and outlet edges along a feed track so as to ensure smooth switching of the blade bodies and the front and rear edges;
s14, fine polishing of air inlet and outlet edges: carrying out longitudinal feed fine polishing in the polishing area D, wherein a feed track is fed clockwise from an air inlet edge in transition from the polishing area A to the polishing area B, or fed clockwise from an air exhaust edge in transition from the polishing area B to the polishing area A;
s15, fine polishing of leaf basin and leaf back: carrying out longitudinal feed finish polishing in a polishing area A, wherein a feed track is fed along the leaf basin profile, and carrying out longitudinal feed finish polishing in a polishing area B, and the feed track is fed along the leaf back profile;
s16, fine polishing of the tenon flow channel and the blade root transfer R: carrying out transverse feed finish polishing on the polishing area C, feeding a feed track from the polishing area A to the polishing area B clockwise, or feeding the feed track from the polishing area B to the polishing area A clockwise, carrying out transverse feed finish polishing on the polishing area F, and feeding the feed track along the profile of the tenon flow passage;
s2, selecting polishing parameters of different areas, and determining different polishing parameters according to the spatial shapes, the spatial sizes and the machining allowance of the different areas of the blade;
s3, verifying the polishing method of the obtained polished blade according to the polishing area, the polishing track and the polishing parameters, and comparing the obtained polished blade with a manual polished blade;
s4, determining a polishing method, and correcting the division of the polished areas, the polishing tracks of all the areas and the polishing parameters of all the areas by combining with a verification test;
and S5, polishing the compressor blades of the medium and small aircraft engines according to the corrected polishing area division, the polishing tracks of the areas and the polishing parameters of the areas.
2. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the polishing tool for rough polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 400 #;
polishing parameters of rough polishing of leaf basin and leaf back: the main shaft of the polishing wheel has the rotating speed of 3550 r/min-3650 r/min, the pre-pressing amount of 0.15 mm-0.25 mm and the feeding amount of 450 mm/min-550 mm/min.
3. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the polishing tool for rough polishing of the tenon flow channel and the blade root switching R adopts a D23r2.5 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 1200 #;
polishing parameters of rough polishing of the tenon flow passage and the blade root switching R: the rotation speed of a main shaft of the polishing wheel is 2400 r/min-2600 r/min, the pre-pressing amount is 0.13 mm-0.17 mm, and the feeding amount is 450 mm/min-550 mm/min.
4. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the polishing tool for finish polishing at the lap joint of the blade body and the air inlet and outlet edges adopts a D23r2.5 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 2000 #;
polishing parameters of finish polishing of the lap joint of the blade body and the air inlet and outlet edges are as follows: the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1700 r/min-1900 r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1400 r/min-1600 r/min, the pre-pressing amount is 0.14 mm-0.16 mm, and the feeding amount is 350 mm/min-450 mm/min.
5. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the polishing tool for finish polishing of the air inlet and outlet edges adopts a D23r2.5 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 2000 #;
polishing parameters of finish polishing of the air inlet and outlet edges: the rotation speed of the main shaft of the polishing wheel at the air inlet side is 1700 r/min-1900 r/min, the rotation speed of the main shaft of the polishing wheel at the air outlet side is 1400 r/min-1600 r/min, the pre-pressing amount is 0.14 mm-0.16 mm, and the feeding amount is 380 mm/min-420 mm/min.
6. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the polishing tool for fine polishing of the leaf basin and the leaf back adopts a D40r7 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 2000 #;
polishing parameters of fine polishing of the leaf basin and the leaf back are as follows: the spindle speed of the polishing wheel is 3800 r/min-4200 r/min, the prepressing amount is 0.2 mm-0.4 mm, and the feeding amount is 650 mm/min-750 mm/min.
7. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the polishing tool for finish polishing of the tenon flow channel and the blade root switching R adopts a D40r2.5 elastic matrix polishing wheel, and the granularity model of the polishing wheel is 1200 #;
polishing parameters of finish polishing of the tenon flow passage and the blade root switching R: the spindle speed of the polishing wheel is 2800 r/min-3200 r/min, the prepressing amount is 0.2 mm-0.4 mm, and the feeding amount is 450 mm/min-550 mm/min.
8. The method for polishing the blades of the small and medium size aeroengine compressors according to claim 1,
the performance parameters of the comparison between the polished blade and the manual polished blade comprise: surface texture, surface roughness, profile, metallographic structure, frequency, weight, residual stress, high cycle fatigue life.
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| EP2047343A1 (en) * | 2006-07-24 | 2009-04-15 | Rolls Royce Plc | Control of a machining operation |
| CN102476344A (en) * | 2010-11-22 | 2012-05-30 | 沈阳黎明航空发动机(集团)有限责任公司 | Polishing and grinding method of titanium alloy blades |
| CN109623591A (en) * | 2018-11-27 | 2019-04-16 | 中国航发沈阳黎明航空发动机有限责任公司 | A kind of compressor blade holotype face numerical control grinding and polishing method |
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