镍基高温合金叶片类曲面砂带高效精密磨削机理与轨迹规划研究

Blade surfaces with nickel-base superalloy are widely used in the aircraft engine, the industrial gas turbine, etc. CNC abrasive belt is an effective means to achieve the high efficiency and precision grinding. In view of the present situation in this field that the domestic research is blank, and the abroad implement strictly confidential, aiming at high efficiency and precision grinding by CNC abrasive belt for blade surfaces with nickel-base superalloy, this project focuses on the basic scientific research about material removal mechanism, workpiece surface integrity, abrasive belt wear mechanism, multi-objective optimization of process parameters and tool path planning of blade surfaces, with the purpose to: understand quantitatively and master the complicated nonlinear mechanism of the elastic grinding process; reveal the relationship between process parameters and material removal rate, grinding temperature, workpiece surface integrity and abrasive belt wear, etc; carry out the multi-objective optimization of process parameters based on material removal rate, workpiece surface integrity and abrasive belt life; form systematic theories and methods of tool path planning for high efficiency and precision grinding of blade surfaces based on multiple factors such as geometric accuracy, material removal rate, dynamic characteristic of grinding machine, grinding force, elastic contact characteristic of abrasive belt, abrasive belt wear, etc. This project can provide theoretical support to solve the problem of high efficiency and precision grinding by CNC abrasive belt for the domestic blade surfaces with nickel-base superalloy.

镍基高温合金叶片类曲面广泛应用于航空发动机和工业燃气轮机等领域，数控砂带是实现其高效精密磨削的有效手段。针对该领域国内研究尚属空白、国外实施绝对保密的现状，本项目以镍基高温合金叶片类曲面数控砂带高效精密磨削为研究对象，围绕材料去除机理、工件表面完整性、砂带磨损机理、工艺参数多目标优化和叶片类曲面轨迹规划等方面开展基础科学研究，定量认识和掌握这一弹性磨削过程的复杂非线性作用机制，揭示工艺参数与材料去除率、磨削温度、表面完整性、砂带磨损等因素之间的关系规律，实现基于材料去除率、工件表面完整性和砂带寿命的工艺参数多目标优化，形成综合考虑几何精度、材料去除率、磨床动态特性、磨削力、砂带弹性接触特征和砂带磨损等多种因素的叶片类曲面高效精密轨迹规划系统理论和方法，为最终解决国内镍基高温合金叶片类曲面的数控砂带高效精密磨削问题提供理论支撑。

镍基高温合金叶片类曲面广泛应用于航空发动机和工业燃气轮机等领域，数控砂带是实现其高效精密磨削的有效手段。针对该领域国内研究尚属空白、国外实施绝对保密的现状，本项目以镍基高温合金叶片类曲面数控砂带高效精密磨削为研究对象，围绕材料去除机理、工件表面完整性、砂带磨损机理、复杂接触行为等方面开展了基础科学研究，提出了一种包含功率谱密度分析、自相关函数分析和磨粒特征统计学分析的评价方法，实现了从宏观整体到局部磨粒对砂带表面形貌特征的定性和定量评价；建立了材料去除深度和去除量模型，预测值与试验值较好的吻合；开展了工艺参数对砂带磨后工件表面残余应力的影响研究，发现工件划痕表层某方向残余应力沿深度方向的分布规律呈先拉后压，最后再次恢复至稳定轻微拉应力的形式；建立了砂带磨削接触区磨粒激振力模型以及砂带磨削声信号与激振力传递函数模型，指出砂带振动的激振力主要来源于砂带磨粒切入切出工件时所产生的激振力，其频带主要分布于中高频部分，部分频段能量与反映砂带磨损程度的材料去除率之间具有强相关性（高达95%）；分析了砂带磨削中内凹型接触轮与圆柱面的接触几何关系，建立了宏观静态接触理论模型，实现了接触区域边界曲线和接触应力分布的计算；对叶片类曲面接触行为进行了研究，发现当接触面为凸面时，曲率正交时接触面积最小，当接触面为凹面时，曲率正交时发生最大干涉，在凹面时的接触压力小于凸面，同时接触压力与接触面的曲率半径成负相关，即接触面弯曲程度越大，接触压力越大。相关研究结论有助于定量认识和掌握砂带磨削这一弹性磨削过程的复杂非线性作用机制，为形成综合考虑几何精度、材料去除率、磨削力、砂带弹性接触特征和砂带磨损等多种因素的叶片类曲面高效精密轨迹规划系统理论和方法提供了理论支撑。