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On the predictive modeling of surface micro-topography in vibratory polishing of aeronautic gear considering initial workpiece topography

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Abstract

The functional behaviors and service performances of aeronautic gears are significantly determined by its surface integrity. Vibratory polishing, as one of the most promising ultra-high-precision finishing approaches for free-form surfaces, shows strong capability to improve the surface integrity of aeronautic gears. In order to gain a scientific insight into the surface generation, a three-dimensional predictive model is proposed in this study for the vibratory polishing surfaces of aeronautic gear considering the initial workpiece topography. The single abrasive particle is regarded as a micro-tool and the removed material is quantitatively determined based on the calculation of Brinell hardness. Then, the predictive model of the surface micro-topography can be developed on the basis of the initial workpiece topography and the interaction between workpiece and abrasive particles. The vibratory polishing tests are further carried out to verify the validity of the proposed surface topography prediction model. The results indicate that the predicted three-dimensional surface roughness agrees well with that of the measured data with an average error of 6.35%. Finally, parametric analysis is conducted to investigate the influence of polishing time, surface hardness, and abrasive particle diameter on the surface parameters. The preliminary work presented in this study is not only helpful to lay a scientific foundation for the more in-depth understanding of the surface generation and material removal mechanism in vibratory polishing, but also meaningful to provide an engineering guidance for the prediction of surface quality and optimization of machining parameters.

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Data availability

The datasets or material used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This work was supported by the National Key R&D Program of China (Grant No. 2020YFB2010200), the National Science and Technology Major Project (2017-VII-0003–0096), the Defense Industrial Technology Development Program (No. JCKY2020213B006), and the National Key Laboratory of Science and Technology on Helicopter Transmission (Grant No. HTL-0-21G04).

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Authors and Affiliations

  1. State Key Laboratory of High Performance Complex Manufacturing, College of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, Hunan, China

    Wen Shao, Yihui Hou, Jinyuan Tang, Qingsong Liu & Han Ding

  2. National Key Laboratory of Science and Technology On Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Zhengmingqing Li

Authors
  1. Wen Shao
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  2. Yihui Hou
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  3. Jinyuan Tang
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  4. Qingsong Liu
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  5. Han Ding
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  6. Zhengmingqing Li
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Contributions

SW: software, data curation, conceptualization, methodology, original draft preparation; YH: conceptualization, investigation, data curation, writing—review and editing; JT: data curation, writing—review and editing; QL: writing—review and editing; HD: conceptualization, methodology, investigation, writing—review and editing; ZL: writing—review and editing.

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Correspondence to Wen Shao.

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Shao, W., Hou, Y., Tang, J. et al. On the predictive modeling of surface micro-topography in vibratory polishing of aeronautic gear considering initial workpiece topography. Int J Adv Manuf Technol 126, 1553–1565 (2023). https://doi.org/10.1007/s00170-023-11134-5

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  • DOI: https://doi.org/10.1007/s00170-023-11134-5

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