Technology on Flexible Polishing for Leading and Trailing Edges of Blisk Blades

doi:10.3969/j.issn.1004-132X.2025.12.030

Abstract

Abstract:

Aiming at the problems of low polishing efficiency， difficulty in ensuring surface quality and profile accuracy of the leading and trailing edges of aero-engine blades， a study on the automated polishing processes for the leading and trailing edges of blisk blades was conducted. The influence of processing parameters on the size of the polishing contact area at the leading and trailing edges was analyzed， and a predictive model for normal polishing force was established， with a root mean square error of 1.24 N between the predicted and actual values. Based on the Preston equation， the effects of compression amount， spindle speed， sponge abrasive wheel radius， feed rate， and abrasive grit size on material removal in the polishing contact area were modeled. Experiments were conducted using the proposed predictive model for material removal depth at the leading and trailing edges. The experimental results show that the value of surface roughness of the blade leading and trailing edges is reduced to 0.18 μm， verifying that the predictive model may effectively forecast material removal depth. Additionally， the sponge abrasive wheel is proven to effectively improve the surface roughness of the blade leading and trailing edges.

Key words: leading and trailing edges of blisk blade, polishing contact zone, material removal, roughness

摘要：

针对航空发动机叶片前后缘抛光加工效率低、表面质量及轮廓精度难以保证等问题开展了整体叶盘叶片前后缘自动化抛光工艺研究。分析了工艺参数对前后缘抛光接触区域尺寸的影响规律，建立了法向抛光力预测模型，预测值与实际值均方根误差为1.24 N；基于Preston方程对抛光接触区域内压缩量、主轴转速、海绵砂圈半径、进给速度和磨具粒度对材料去除的影响规律进行了建模。基于所提出的前后缘抛光材料去除深度预测模型进行实验，结果表明，叶片前后缘表面粗糙度降低至0.18 μm，验证了该预测模型可以有效地预测材料去除深度，海绵砂圈可以有效改善叶片前后缘粗糙度。

关键词: 整体叶片前后缘, 抛光接触区域, 材料去除深度, 粗糙度

CLC Number:

V263.1

Chengshuo LIU, Xiaojun LIN, Bo ZHONG, Wenhui DENG. Technology on Flexible Polishing for Leading and Trailing Edges of Blisk Blades[J]. China Mechanical Engineering, 2025, 36(12): 3047-3056.

刘承硕, 蔺小军, 钟波, 邓文辉. 整体叶盘叶片前后缘柔性抛光技术[J]. 中国机械工程, 2025, 36(12): 3047-3056.

Figures/Tables 26

Fig.1 Sponge sanding disc tool integrated structure

Fig.2 Virtual penetration method

Fig.3 Contact state between sponge sanding disc and leading and trailing edges during polishing

Fig.4 Virtual contact zone

Fig.5 Polish contact state between sponge sanding disc and leading and trailing edges in Oyz cross-section

Fig.6 Polish contact state between sponge sanding disc and leading and trailing edges in Oxz cross-section

Fig.7 Sing-point polishing contact zone of sponge sanding disc on leading edge

Tab.1 Orthogonal experimental parameter selection

实验次数	压缩量a_p/mm	海绵砂圈半径R/mm	抛光接触区域曲率半径r/mm
1	0.6	10	0.2
2	0.2	8	0.4
3	0.6	6	0.4
4	0.2	10	0.3
5	0.4	10	0.4
6	0.6	8	0.3
7	0.4	8	0.2
8	0.4	6	0.3
9	0.2	6	0.2

Tab.2 Contraction ratio of major and minor axes in orthogonal experiment

实验次数	长轴长度2a/mm		收缩比例	短轴长度b₁/mm		收缩比例	短轴长度b₂/mm		收缩比例
实验次数	虚拟区域	实验区域	收缩比例	虚拟区域	实验区域	收缩比例	虚拟区域	实验区域	收缩比例
1	6.824	4.903	0.719	1.187	0.566	0.476	0.548	0.266	0.486
2	3.556	2.561	0.720	1.448	0.721	0.498	0.692	0.332	0.479
3	5.231	3.732	0.714	3.688	1.814	0.492	1.657	0.841	0.508
4	3.980	2.685	0.675	0.545	0.274	0.503	0.260	0.130	0.498
5	5.600	3.829	0.684	2.734	1.368	0.501	1.074	0.534	0.497
6	6.080	4.182	0.688	1.352	0.687	0.508	0.643	0.331	0.514
7	4.996	3.532	0.707	0.806	0.409	0.507	0.417	0.210	0.502
8	4.308	2.915	0.677	0.935	0.454	0.486	0.466	0.234	0.503
9	3.073	2.180	0.709	0.533	0.266	0.500	0.197	0.101	0.512

Tab.3 Normal polishing force under different process parameter combinations

实验序号	抛光接触位置	海绵砂圈半径R/mm	压缩量 a_p/mm	接触区域面积S/mm²	法向抛光力F/N
1	1	6	0.15	0.7388	2.4826
2	2			1.4953	4.4497
3	3			3.0287	7.9805
4	1		0.2	0.9730	3.4378
5	2			2.0270	6.3109
6	3			4.1216	11.3551
7	1		0.25	1.2023	4.4182
8	2			2.5781	8.3068
9	3			5.3936	15.3027
10	1		0.3	1.4341	5.4386
11	2			3.1394	10.4020
12	3			7.1964	20.6680
13	1	8	0.15	0.8544	1.8803
14	2			1.7294	3.3705
15	3			3.5028	6.0449
16	1		0.2	1.1259	2.6051
17	2			2.3455	4.7823
18	3			4.7693	8.6048
19	1		0.25	1.3920	3.3496
20	2			2.9848	6.2976
21	3			6.2445	11.6013
22	1		0.3	1.6613	4.1251
23	2			3.6367	7.8896
24	3			8.3363	15.6760
25	1	10	0.15	0.9563	1.5157
26	2			1.9353	2.7165
27	3			3.9199	4.8720
28	1		0.2	1.2603	2.1001
29	2			2.6257	3.8555
30	3			5.3389	6.9370
31	1		0.25	1.5588	2.7011
32	2			3.3424	5.0784
33	3			6.9926	9.3553
34	1		0.3	1.8573	3.3220
35	2			4.0737	6.3639
36	3			9.3380	12.6445

Fig.8 Influence law of sponge sanding disc radius on polishing dorce

Fig.9 Standardized residual distribution

Fig.10 Scatter plot of predicted and measured values

Fig.11 Polishing pressure distribution in contact zone

Fig.12 Material removal integral in polishing contact zone

Fig.13 Contact state between sponge sanding disc and cylindrical test coupon

Fig.14 Calibration experiment for Preston coefficient

Tab.4 Experimental parameters for Preston coefficient calibration

序号	压缩量a_p/mm	主轴转速 ω/（r·min $- 1$ ）	接触面积 S/mm²	粒度P_#	进给速度 v_f /（mm·min $- 1$ ）	去除深度 h（0）/μm	系数c	Preston系数K₁
1	0.2	3000	0.614	3000	250	0.31	$-$ 1.3692	263.378
2	0.2	4000	0.614	5000	250	0.20
3	0.2	5000	0.614	3000	250	0.49
4	0.2	6000	0.614	5000	250	0.30

Tab.4 Experimental parameters for Preston coefficient calibration

序号	压缩量a_p/mm	主轴转速 ω/（r·min $- 1$ ）	接触面积 S/mm²	粒度P_#	进给速度 v_f /（mm·min $- 1$ ）	去除深度 h（0）/μm	系数c	Preston系数K₁
1	0.2	3000	0.614	3000	250	0.31	$-$ 1.3692	263.378
2	0.2	4000	0.614	5000	250	0.20
3	0.2	5000	0.614	3000	250	0.49
4	0.2	6000	0.614	5000	250	0.30

Tab.5 Process parameters for material removal profile height verification experiment

序号	压缩量 a_p /mm	进给速度 v_f/（mm·min $- 1$ ）	主轴转速 ω/（r·min $- 1$ ）	磨具粒度P_#	海绵砂圈半径 R/mm	工件半径 R_m/mm
1	0.15	250	5000	5000	10	0.3
2	0.15	350	7000	5000	10	0.3
3	0.25	250	7000	5000	10	0.3
4	0.25	350	5000	5000	10	0.3

Tab.5 Process parameters for material removal profile height verification experiment

序号	压缩量 a_p /mm	进给速度 v_f/（mm·min $- 1$ ）	主轴转速 ω/（r·min $- 1$ ）	磨具粒度P_#	海绵砂圈半径 R/mm	工件半径 R_m/mm
1	0.15	250	5000	5000	10	0.3
2	0.15	350	7000	5000	10	0.3
3	0.25	250	7000	5000	10	0.3
4	0.25	350	5000	5000	10	0.3

Fig.15 Experimental verification of material removal profile height

Fig.16 Surface feature profile measurement

Fig.17 Validation and comparison of material removal profile height prediction model

Tab.6 Simulation parameters

序号	压缩量a_p/mm	进给速度v_f/ （mm·min $- 1$ ）	主轴转速 ω/（r·min $- 1$ ）	磨具粒度 P_#	海绵砂圈半径 R/mm
1	0.15，0.20，0.25	300	5000	5000	10
2	0.2	250，300，350	5000	5000	10
3	0.2	300	3000，5000，7000	5000	10
4	0.2	300	5000	3000，5000	10
5	0.2	300	5000	5000	6，8，10

Tab.6 Simulation parameters

序号	压缩量a_p/mm	进给速度v_f/ （mm·min $- 1$ ）	主轴转速 ω/（r·min $- 1$ ）	磨具粒度 P_#	海绵砂圈半径 R/mm
1	0.15，0.20，0.25	300	5000	5000	10
2	0.2	250，300，350	5000	5000	10
3	0.2	300	3000，5000，7000	5000	10
4	0.2	300	5000	3000，5000	10
5	0.2	300	5000	5000	6，8，10

Fig.18 Simulation results of material removal profile height

Fig.19 Surface texture of blade leading/trailing edges before and after polishing

Fig.20 Surface roughness comparison before and after polishing

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