风扇整体叶盘旋振复合抛磨的流场调控与加工效果OA

The surface integrity and finishing uniformity of fan blisks have a significant effect on the service performance and lifespan of aeroengines.However,after finishing,there are still problems such as poor finishing uniformity and local under-finishing or over-finishing.To solve this issue,the work aims to study the flow field regulation and finishing effects on the vibratory-rotary finishing for fan blisks. Based on the normal force and action mechanisms of granular media,a"configuration-motion"combined flow field regulation scheme for granular media was proposed,which integrated"container wall configuration,blade expansion configuration,and container adaptation rotation".These schemes respectively solved the problems of poor finishing uniformity along the blade tip-root direction,the inlet/outlet edge to blade body direction,as well as the blade back and basin surfaces.The effects of different regulation schemes on the normal force,wear depth and surface roughness on fan blisks were studied by discrete element simulations and finishing experiments,and the finishing effects under the optimal regulation schemes were revealed. Compared with before regulation,the container wall and blade expansion configurations increased the uniformity of normal force on the blade back and basin surfaces by 2.58%and 7.34%,55.17%and 55.80%,respectively.The uniformity was further improved after the container adaptation rotation.Furthermore,the increase in the uniformity of normal force induced an improvement of wear depth.Under the optimal regulation scheme,the uniformity of wear depth decreased from 1.288 and 0.573 to 0.258 and 0.268,corresponding to enhancement rates of 79.97%and 53.23%,respectively.At the same time,the consistency of back and basin surfaces was significantly enhanced.The validity of the regulation schemes was proved through finishing experiments.Compared with that before the regulation,the uniformity of surface roughness such as Ra,Rq and Rz of the blisk surface after the regulations of container wall and blade expansion configurations was improved.After the container adaptation rotation,the finishing uniformity and consistency of the blade back and basin surfaces were significantly improved.The surface roughness of back and basin surfaces decreased from Ra 0.939 µm and Ra 0.918 µm to Ra 0.259 µm and Ra 0.252 μm,with the variation coefficients of 0.068 and 0.048,which met the finishing requirements of fan blisks. After finishing with the optimal regulation schemes,the surface morphology of the grinding texture before finishing was completely removed,the surface became smooth,the height difference between the peaks and troughs decreased significantly,and the surface tended to be isotropic.Meanwhile,the surface integrity indicators exhibited a comprehensive improvement,the residual compressive stress increased from-359.17 MPa and-373.86 MPa to-535.30 MPa and-554.99 MPa.Meanwhile,the uniformity increased by 63.92%and 75.72%compared with that before finishing.For microhardness,the back surface increased from 237.1HV0.5 to 307.3HV0.5,while the basin surface increased from 225.4HV0.5 to 320.5HV0.5.The uniformity also significantly increased by 42.13%and 54.41%.In addition,the deviations of the surface accuracy were all less than 0.08 mm,and the data of each measurement point indicated that the vibratory-rotary finishing process had good uniformity. The results show that the vibratory-rotary finishing process and the regulation scheme of granular media flow field can comprehensively improve the surface integrity indexes and significantly enhance the finishing uniformity and consistency of the blade back and basin surfaces.At the same time,the profile accuracy is not damaged.This study provides a research method and feasible solution for the high surface integrity and uniform consistency finishing of fan blisks.