航空发动机整体叶盘滚磨光整加工的颗粒流场精准构造理论研究

As a key component of the fourth-generation aeroengine with advanced performance, the blisk with higher surface integrity is required. Its manufacturing technologies for improving performance have always been a globally recognized major technical problem for aeroengine. At present, exploratory manufacturing technologies for improving blisk performance are obviously inadequate in the comprehensive improvement degree of the surface integrity indexes, the process practicality, and so on. After mass finishing processes with great potential was used to finish the blisk, the finishing effects are obvious and the efficiency is high, but there exists the ununiform finishing problem for blade basin and blade back of the same flow channel currently. Therefore, after fully analyzing the geometric configuration and finishing requirements of the blisk, a new idea, constructing particle flow field by setting up diversion island in the flow channel, is proposed. Based on the soft material characteristics of the media for mass finishing processes, the kinematics and dynamics behavior of the finishing media with different scale are analyzed using interdisciplinary theories and methods. Then, the way of regulating flow field by setting diversion island in the flow channel is rationally explored, and the characteristics of the particle flow field and the force of the channel surface are constructed. Finally, the material removal model of the blisk is built by combining the quantitative analysis of the relative speed with the force between the blisk and media, and the regulative strategy of precise finishing for the blisk is formed. So, new mass finishing process scheme of the blisk is determined, which can be used to solve the finishing problem of the blisk effectively and provide the theory for particle flow precise machining of high performance parts.

整体叶盘作为第四代先进性能航空发动机的核心部件，表面完整性要求越来越高，其成性制造技术一直是全球公认的航空发动机重大技术难题。目前同步探索的整体叶盘成性制造技术在表面完整性指标综合改善程度、工艺实用性等方面明显不足；滚磨光整工艺发展潜力巨大，加工整体叶盘的效果明显、效率高，但目前存在同一流道内叶盆、叶背部位加工不均匀的难题。为此，在分析整体叶盘几何构形和加工要求的基础上，提出流道内设置导流半岛构造颗粒流场的思想；基于滚磨光整加工介质群的软物质特性，采用多学科理论和方法，分析颗粒介质不同尺度的运动学和动力学行为，探索流道内合理设置导流半岛调控流场的方式，构造流道边界的颗粒流场特征、流道壁面的作用力特征，形成相对速度和作用力的定量化描述，耦合构建材料去除模型，确定精准加工的调控策略，最终形成整体叶盘滚磨光整加工新方案，用以解决整体叶盘的光整加工难题，为颗粒流在高性能零件精密加工的应用提供理论。

整体叶盘作为第四代先进性能航空发动机的核心部件，表面完整性要求越来越高。为有效解决整体叶盘光整加工的难题，基于光整加工理论、离散单元及其耦合方法、多种测试分析技术，以风扇整体叶盘为主要研究对象，深入开展了理论分析、模拟仿真、试验研究。为准确揭示滚抛磨块群强制动态特性，提出湿式颗粒介质的参数测试和标定方法、动态力传感和PIV技术测试颗粒介质作用力和速度的方法，开发了包含表面微观形貌信息的数字孪生表面模型、滚磨光整加工过程颗粒体系力链检索算法、用于滚磨光整加工工件表面残余应力的模拟方法，创设组合方案得出滚抛磨块与工件之间的修正接触力，构建出滚抛磨块颗粒体系的力链网络图并描述了力链的演化及其动力学规律。使用多种表征方式分析了滚抛磨块群的形成机理、运动特征、作用特点及调控机制，明确了特征可控的滚抛磨块群运动学及动力学行为，实现了颗粒流场的有效模拟。基于整体叶盘几何构形和光整加工现实需求，建立了动力学模型和空间速度模型，模拟仿真并试验测试了颗粒介质的运动特征；基于相似理论和量纲分析法提出一种用于构建滚磨光整加工试验模型的方法，指导试验装置搭建；提出基于工件特征反馈的振动式滚磨光整设备设计方法，进行了国产立式振动设备的参数化设计；制定了整体叶盘回转辅助水平振动抛磨新方案，构造了流道内颗粒介质的流场特征、流道壁面的作用力特征，提出多种基于适形适性构想的颗粒流场调控策略；确定了工艺参数对表面粗糙度、材料去除量、微观形貌、显微硬度和残余应力等表面完整性主要参数的影响规律，测试分析了耐磨性、疲劳性等使用性能，为复杂构型零件的形性协同高效精准加工提供了新的思路和方法。拓展研究了不同滚抛磨块材质、不同磨液成分的加工效果，并提出了含氧化剂磨液和纳米粒子磨液两种新型磨液体系，发现深冷处理可以有效改善钛合金试件滚磨光整加工后的表面完整性，进一步满足高端装备高性能零件日益增长的高品质光整加工需求。