目的 针对风扇整体叶盘抛磨均匀性不足的问题,开展旋振复合抛磨工艺的流场调控与加工效果研究。方法 提出“容器器壁构形、叶片拓展构形、容器适配回转”的颗粒介质流场调控方案。离散元仿真和抛磨实验分析不同调控方案对风扇整体叶盘型面法向力、磨损深度和表面粗糙度的影响,揭示最优调控方案时的加工效果。结果 相较于调控前,容器器壁构形使得叶背和叶盆型面法向力均匀性分别提高2.58%和7.34%,而叶片拓展构形使得均匀性分别提高55.17%和55.80%。容器适配回转调控后均匀性进一步改善,进而显著提高磨损深度的均匀性,叶背和叶盆型面变异系数分别从1.288和0.573下降至0.258和0.268,同时两型面之间的一致性增强。抛磨后叶背和叶盆型面表面粗糙度值分别从0.939 μm和0.918 μm下降至0.259 μm和0.252 μm,变异系数分别为0.068和0.048,满足抛磨需求。此外,表面完整性指标综合改善,叶背和叶盆型面残余压应力分别从‒359.17 MPa和‒373.86 MPa增加至‒535.30 MPa和‒554.99 MPa,而维氏硬度分别由237.1HV0.5和225.4HV0.5增加至307.3HV0.5和320.5HV0.5。同时,尺寸偏差均低于0.08 mm,各测点数据表明旋振复合抛磨工艺具有较好的加工均匀性。结论 旋振复合抛磨工艺和流场调控方案可综合改善风扇整体叶盘表面完整性指标,并提高叶背和叶盆型面的均匀一致性,且并未破坏其型面精度。本研究为风扇整体叶盘的高表面完整性和均匀一致性抛磨提供研究方法和可行方案。
Abstract
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.
关键词
旋振复合抛磨 /
风扇整体叶盘 /
表面完整性 /
加工均匀性 /
颗粒介质流场 /
构形-运动调控
Key words
vibratory-rotary finishing /
fan blisk /
surface integrity /
processing uniformity /
flow field of granular media /
configuration-motion regulation
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基金
国家自然科学基金（51875389,52575527,52575523）
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