复杂曲面自适应柔性抛光表面完整性控制理论与方法

The fatigue of complicated structure components largely depends on their surface integrity. While the polishing process is an essential one to remove the milling traces and improve the surface integrity. Therefore, more and more researches on surface integrity controlling are carried out by international scholars at present. Based on the study of surface features, material properties, polishing temperature, polishing efficiency and tool life, the adaptive flexible polishing process for TC17 and GH4169 blisks is researched in this project. The influence of polishing parameters on surface integrity are studied firstly. And then the adaptive flexible polishing process are researched and optimized. According to the study of influence rule of polishing process and surface integrity, the region control method of polishing parameters and the key surface integrity parameters is put forward. The prediction model of coupled mechanism for polishing parameters and surface integrity is established. Through the optimization and controlling of polishing parameters, the stable ranges of polishing parameters and surface integrity parameters are constructed. Finally, the basic theory and data of polishing process controlling are obtained so as to improve the surface integrity. The expected achievements of this project have academic guidance meaning and application for further research and development of complex surface components.

表面完整性决定了复杂曲面构件的疲劳性能，而抛光是去除其铣削加工刀痕、提高表面完整性必不可少的工艺方法，通过抛光表面完整性控制以提高构件的疲劳强度，日益受到国内外学者重视。本项目基于复杂曲面特征、材料性能、抛光温度、抛光效率、磨具寿命，面向TC17/GH4169整体叶盘/叶轮类典型复杂曲面自适应柔性抛光工艺过程，探索工艺参数对抛光表面完整性影响、演化和变化的科学问题，研究并完善自适应柔性抛光工艺方法，掌握工艺参数对抛光工艺过程及抛光表面完整性的影响规律和敏感度，提出基于工艺参数敏感度的抛光工艺过程及抛光表面完整性关键表征参数域控制方法，构建工艺参数对抛光表面完整性影响耦合作用机理预测模型并揭示其作用机理，通过工艺参数优化与控制，确定工艺参数及关键表征参数的稳定域，获得依据表面完整性要求以选择控制工艺参数的基础理论和数据，对国家安全重大科技工程中复杂曲面构件的研制具有理论指导意义和应用价值。

项目以钛合金TC17/高温合金GH4169整体叶盘/叶轮类典型复杂曲面结构件为研究对象，揭示工艺参数对抛光工艺过程及抛光表面完整性影响的作用机理，丰富抛光表面完整性控制基础理论，掌握抛光表面完整性预测、解释和评价方法及控制原理。项目主要的创新性工作有：(1) 针对五轴数控＋柔性磨头＋弹性磨具的抛光工艺过程，提出了典型复杂曲面抛光轨迹规划方法，建立了基于抛光温度、刀具磨损的复杂曲面自适应柔性抛光工艺方法体系。(2) 揭示了如主轴转速、压缩量、进给速度、粒度等工艺参数对表面完整性关键表征参数得影响规律。(3) 通过灵敏度分析了不同工艺参数对表面完整性关键表征参数的影响程度大小，揭示了其对抛光表面完整性影响的作用机理和耦合作用机理。(4) 通过基础实验，建立了工艺参数与表面完整性关键表征参数之间的灵敏度模型，实现了工艺参数向抛光表面完整性的映射及工艺参数对抛光表面完整性影响的预测和控制，确定了工艺参数的稳定域。本项目执行过程中发表论文24篇，其中SCI期刊发表论文17篇，其他核心期刊论文7篇，申请发明专利2项。研究成果为丰富和推动制造业技术发展，实现复杂曲面结构件的表面完整性的控制提供了理论基础。