[go: up one dir, main page]
Skip to main content

Advertisement

Springer Nature Link
Log in

Parameter optimization of five-axis polishing using abrasive belt flap wheel for blisk blade

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

Considering the weak rigidity of blisk blades and the limited accessibility of blisk tunnels, polishing blisk blades is difficult when using tools with poor flexibility and large dimension. Hence, to reduce the Surface roughness (SR) of a blisk blade, five-axis polishing method with Abrasive belt flap wheel (ABFW) is employed to polish the blisk blade based on the analysis of the blisk structure and advantages of ABFW polishing. Polishing experiments based on central composite design are performed using ABFW. Response surface method (RSM) is employed to establish a predictive model between SR and various parameters, including ABFW size, contact force, spindle speed, and feed rate. Analysis of variance is then performed to evaluate the proposed model. The degree of influence of each factor on SR after polishing using ABFW is determined by plotting main effects. The interactions of polishing factors on SR are analyzed by RSM. Optimal parameters are obtained by response surface optimization. Finally, an experiment on blisk blade polishing using ABFW on a five-axis polishing machine is carried out for confirmation. Results indicate that the surface quality of the blisk blade after polishing is significantly improved, with SR being less than 0.4 μm.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Z. Y. Zhao, Investigation and development status of the application technology to improve fatigue behavior of high strength alloys, Engineering Science, 7 (3) (2005) 90–94.

    Article  Google Scholar 

  2. Y. Chen et al., Experiment of surface finishing on aeroengine blisk by magnetic abrasive finishing, Journal of Aerospace Power, 30 (10) (2015) 2323–2330.

    Google Scholar 

  3. L. W. Guo, N. G. Yang and Y. Chen, Influence of magnetic abrasive finishing technology on surface integrity of vane-integrated disk, China Surface Engineering, 26 (3) (2013) 10–14.

    Google Scholar 

  4. Z. W. Du et al., Study on blisk surface polishing by magnetic abrasive finishing, Aeronautical Manufacturing Technology, 20 (2015) 93–95+100.

    Google Scholar 

  5. Y. Huang, G. J. Xiao and L. Zou, Current situation and development trend of polishing technology for blisk, Acta Aeronautica et Astronautica Sinica, 37 (7) (2016) 2045–2064.

    Google Scholar 

  6. Z. W. Liu et al., Experimental on the computer numerical control of belt grinding technology for blisk, Aeronautical Manufacturing Technology, 516 (21) (2016) 93–97.

    Google Scholar 

  7. G. J. Xiao and Y. Huang, Constant-load adaptive belt polishing of the weak-rigidity blisk blade, The International Journal of Advanced Manufacturing Technology, 78 (9) (2015) 1473–1484.

    Article  Google Scholar 

  8. G. J. Xiao, Y. Huang and H. Yi, Experimental research of new belt grinding method for consistency of blisk profile and surface precision, Acta Aeronautica et Astrnautica Sinica, 37 (5) (2016) 1666–1676.

    Google Scholar 

  9. H. X. Zhao, Development of polishing tool for blisk, Dissertation, Jilin University, Changchun, China (2011).

    Google Scholar 

  10. J. H. Duan et al., Adaptive polishing for blisk by flexible grinding head, Acta Aeronautica et Astronautica Sinica, 32 (5) (2011) 934–940.

    Google Scholar 

  11. T. Zhao et al., Surface roughness prediction and parameters optimization in grinding and polishing process for IBR of aero-engine, The International Journal of Advanced Manufacturing Technology, 74 (5) (2014) 653–663.

    Article  Google Scholar 

  12. X. J. Lin et al., NC polishing programming technology of open blisk blade surface, Computer Integrated Manufacturing Systems, 20 (2) (2014) 379–384.

    Google Scholar 

  13. J. H. Yan and L. Li, Multi-objective optimization of milling parameters-the trade-offs between energy, production rate and cutting quality, Journal of Cleaner Production, 52 (4) (2013) 462–471.

    Article  Google Scholar 

  14. M. Sarıkaya and A. Güllü, Taguchi design and response surface methodology based analysis of machining parameters in CNC turning under MQL, Journal of Cleaner Production, 65 (4) (2014) 604–616.

    Article  Google Scholar 

  15. B. Bhardwaj, R. Kumar and P. K. Singh, An improved surface roughness prediction model using Box-Cox transformation with RSM in end milling of EN 353, Journal of Mechanical Science and Technology, 28 (12) (2014) 5149–5157.

    Article  Google Scholar 

  16. N. E. Karkalos, N. I. Galanis and A. P. Markopoulos, Surface roughness prediction for the milling of Ti-6Al-4V ELI alloy with the use of statistical and soft computing techniques, Measurement, 90 (2016) 25–35.

    Article  Google Scholar 

  17. Y. W. Yong et al., Development of a surface roughness model in end milling of nHAP using PCD insert, Ceramics International, 38 (8) (2012) 6865–6871.

    Article  Google Scholar 

  18. M. K. Pradhan, Estimating the effect of process parameters on MRR, TWR and radial overcut of EDMed AISI D2 tool steel by RSM and GRA coupled with PCA, The International Journal of Advanced Manufacturing Technology, 68 (1) (2013) 591–605.

    Article  Google Scholar 

  19. J. X. Ren et al., Research on the NC machining technique of blisk, Acta Aeronautica et Astronautica Sinica, 25 (2) (2004) 205–208.

    Google Scholar 

  20. W. Hao et al., Research on the machining error compensation for the leading and trailing edges of thin-walled blades, Mechanical Science & Technology for Aerospace Engineering, 30 (9) (2011) 1446–1450.

    Google Scholar 

  21. Z. H. Deng, L. L. Wan and R. H. Zhang, Research progresses of high efficiency and precision grinding for hard to machine materials, China Mechanical Engineering, 19 (24) (2008) 3018–3023.

    Google Scholar 

  22. Y. Huang and Z. Huang, Modern abrasive belt grinding technology and engineering application, Chongqing University Press, Chongqing, China (2009).

    Google Scholar 

  23. Y. Lu et al., Experimental research on abrasive belt grinding cu-nickel-aluminum bronze, China Mechanical Engineering, 26 (2) (2015) 167–170+177.

    Google Scholar 

  24. G. J. Xiao and Y. Huang, Equivalent self-adaptive belt grinding for the real-R edge of an aero-engine precisionforged blade, The International Journal of Advanced Manufacturing Technology, 83 (9) (2016) 1697–1706.

    Article  Google Scholar 

  25. M. D. Zhang et al., Robotic belt grinding method for the surface of whole propeller blade, Robot, 37 (3) (2015) 318–326+368.

    Google Scholar 

  26. Y. Huang et al., Research on the key technology of NC abrasive belt grinding for the leading and trailing edges of aero-engine blades, Advanced Materials Research, 565 (2012) 76–81.

    Article  Google Scholar 

  27. X. J. Lin et al., Flexible polishing technology of five-axis NC abrasive belt for blade surface, Acta Aeronautica et Astronautica Sinica, 36 (6) (2015) 2074–2082.

    Google Scholar 

  28. Z. H. Zhang, A comparative study of three central composite designs in response surface methodology, Journal of Shenyang Institute of Aeronautical Engineering, 24 (1) (2007) 87–91.

    Google Scholar 

  29. T. Thepsonthi and T. Özel, Multi-objective process optimization for micro-end milling of Ti-6Al-4V titanium alloy, The International Journal of Advanced Manufacturing Technology, 63 (9) (2012) 903–914.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, China

    Junfeng Zhang, Yaoyao Shi, Xiaojun Lin & Zhishan Li

Authors
  1. Junfeng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yaoyao Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xiaojun Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhishan Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Junfeng Zhang.

Additional information

Recommended by Editor Chongdu Cho

Junfeng Zhang studied at the Northwestern Polytechnical University, Xi’an, China. His research fields include electromechanical engineering and automation and adaptive polishing technologies for complex surfaces.

Yaoyao Shi is a Professor of Northwestern Polytechnical University, Xi’an, China. His research fields include electromechanical engineering and automation, high-efficiency NC machining, and adaptive polishing technologies for complex surfaces.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, J., Shi, Y., Lin, X. et al. Parameter optimization of five-axis polishing using abrasive belt flap wheel for blisk blade. J Mech Sci Technol 31, 4805–4812 (2017). https://doi.org/10.1007/s12206-017-0928-0

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-017-0928-0

Keywords