Skip to main content
SpringerLink
Log in

Machining behavior and experimental investigation of ultrasonic vibration assisted belt flapwheel flexible polishing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The integral blisk has been widely used in aerospace, and its structural performance is inextricably linked to the blade surface quality. To improve the surface integrity of polished surface, ultrasonic vibration assisted belt flapwheel flexible polishing (UBFP) is proposed. In this study, the polishing principle of UBFP and the effects of vibration on surface generation are investigated, and kinematic analyses and trajectory simulations are performed. Furthermore, the influences of the main processing parameters on the polishing force and surface roughness in UBFP are explored experimentally, and the sensitivity of the main parameters is distinguished by multi-parameter relative sensitivity analysis based on Monte Carlo simulation. The results show that the ultrasonic vibration contributes to the polishing process primarily through kinematic state changing and trajectories interlacing of abrasives. Compared with conventional belt flapwheel flexible polishing, the polishing force decreases by 15.72% and the surface roughness decreases by 17.39%. The compression depth is the most sensitive parameter in the process of UBFP. This study demonstrates the feasibility of UBFP and provides a theoretical and experimental reference for improving the polishing surface quality of the blisk blade.

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

Access this article

Log in via an institution

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

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Li B, Dai C, Ding W, Yang C, Li C, Kulik O, Shumyacher V (2021) Prediction on grinding force during grinding powder metallurgy nickel-based superalloy FGH96 with electroplated cbn abrasive wheel. Chinese J Aeronaut 34(08):65–74. https://doi.org/10.1016/j.cja.2020.05.002

    Article  Google Scholar 

  2. Xiao G, Huang Y (2015) Constant-load adaptive belt polishing of the weak-rigidity blisk blade. Int J Adv Manuf Tech 78:1473–1484. https://doi.org/10.1007/s00170-014-6724-4

    Article  Google Scholar 

  3. Li C, Piao Y, Meng B, Hu Y, Li L, Zhang F (2022) Phase transition and plastic deformation mechanisms induced by self-rotating grinding of GaN single crystals. Int J Mach Tool MANU 172:103827. https://doi.org/10.1016/j.ijmachtools.2021.103827

    Article  Google Scholar 

  4. Li C, Li X, Wu Y, Zhang F, Huang H (2019) Deformation mechanism and force modelling of the grinding of YAG single crystals. Int J Mach Tool MANU 143:23–37. https://doi.org/10.1016/j.ijmachtools.2019.05.003

    Article  Google Scholar 

  5. Fu Y, Gao H, Wang X, Guo D (2017) Machining the integral impeller and blisk of aero-engines: a review of surface finishing and strengthening technologies. Chin J Mech Eng-En 30:528–543. https://doi.org/10.1007/s10033-017-0123-3

    Article  Google Scholar 

  6. Krack M, Salles L, Thouverez F (2017) Vibration prediction of bladed disks coupled by friction joints. Arch Comput Method E 24:589–636. https://doi.org/10.1007/s11831-016-9183-2

    Article  Google Scholar 

  7. Chen Z, Quan F, Cui Y, Cui C, Ye H (2021) Study of the effect of surface roughness on fatigue strength of GH4169 based on indirect evaluation of the notch root radius. Int J Fatigue 152:106440. https://doi.org/10.1016/j.ijfatigue.2021.106440

    Article  Google Scholar 

  8. Liu X, Wang W, Jiang R, Xiong Y, Lin K (2020) Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites. Adv Manuf 8:252–264. https://doi.org/10.1007/s40436-020-00294-2

    Article  Google Scholar 

  9. Tan L, Yao C, Zhang D, Ren J, Zhou Z, Zhang J (2020) Evolution of surface integrity and fatigue properties after milling, polishing, and shot peening of TC17 alloy blades. Int J Fatigue 136:105630. https://doi.org/10.1016/j.ijfatigue.2020.105630

    Article  Google Scholar 

  10. Kubota A, Nagae S, Motoyama S (2020) High-precision mechanical polishing method for diamond substrate using micron-sized diamond abrasive grains. Diam Relat Mater 101:107644. https://doi.org/10.1016/j.diamond.2019.107644

    Article  Google Scholar 

  11. Shao Q, Lyu BH, Yuan JL, Wang X, Ke MF, Zhao P (2021) Shear thickening polishing of the concave surface of high-temperature nickel-based alloy turbine blade. J Market Res 11:72–84. https://doi.org/10.1016/j.jmrt.2020.12.112

    Article  Google Scholar 

  12. Luo M, Hah C, Haffez HM (2019) Four-axis trochoidal toolpath planning for rough milling of aero-engine blisks. Chinese J Aeronaut 32(8):2009–2016. https://doi.org/10.1016/j.cja.2018.09.001

    Article  Google Scholar 

  13. Zhang J, Shi Y, Lin X, Lin X, Li Z (2017) Five-axis abrasive belt flap wheel polishing method for leading and trailing edges of aero-engine blade. Int J Adv Manuf Tech 93:3383–3393. https://doi.org/10.1007/s00170-017-0717-z

    Article  Google Scholar 

  14. Lin X, Xin X, Yang R, Lei Z, Sun L, Yang B, Bai C, Yan Y (2021) Sensitivity analysis and parameter interval optimization for residual stress in polishing process of GH4169 blisk blade. J Mech Sci Technol 35(2):515–524. https://doi.org/10.1007/s12206-021-0110-6

    Article  Google Scholar 

  15. Yang Z, Zhu L, Lin B, Zhang G, Ni C, Sui T (2019) The grinding force modeling and experimental study of ZrO2 ceramic materials in ultrasonic vibration assisted grinding. Ceram Int 45:8873–8889. https://doi.org/10.1016/j.ceramint.2019.01.216

    Article  Google Scholar 

  16. Dogra M, Sharma V, Dureja J, Singh D, Singh G (2018) Environment-friendly technological advancements to enhance the sustainability in surface grinding-a review. J Clean Prod 197:218–231. https://doi.org/10.1016/j.jclepro.2018.05.280

    Article  Google Scholar 

  17. Zhu D, Tao R, Xiao R, Pan L (2020) Solving the runner blade crack problem for a Francis hydro-turbine operating under condition-complexity. Renew Energ 149:298–320. https://doi.org/10.1016/j.renene.2019.12.057

    Article  Google Scholar 

  18. Lin J, Han J, Zhou X, Hao Z, Lu M (2016) Study on predictive model of cutting force and geometry parameters for oblique elliptical vibration cutting. Int J Mech Sci 117:43–52. https://doi.org/10.1016/j.ijmecsci.2016.08.004

    Article  Google Scholar 

  19. Misra A, Pandey M, Dixit U (2017) Modeling of material removal in ultrasonic assisted magnetic abrasive finishing process. Int J Mech Sci 131–132:853–867. https://doi.org/10.1016/j.ijmecsci.2017.07.023

    Article  Google Scholar 

  20. Ning F, Cong W, Pei Z, Treadwell C (2016) Rotary ultrasonic machining of CFRP: a comparison with grinding. Ultrasonics 66:125–132. https://doi.org/10.1016/j.ultras.2015.11.002

    Article  Google Scholar 

  21. Liang Z, Wu Y, Wang X, Zhao W (2010) A new two-dimensional ultrasonic assisted grinding (2D-UAG) method and its fundamental performance in monocrystal silicon machining. Int J Mach Tool Manu 50(8):728–736. https://doi.org/10.1016/j.ijmachtools.2010.04.005

    Article  Google Scholar 

  22. Wang Y, Lin B, Wang S, Cao X (2014) Study on the system matching of ultrasonic vibration assisted grinding for hard and brittle materials processing. Int J Mach Tool Manu 77:66–73. https://doi.org/10.1016/j.ijmachtools.2013.11.003

    Article  Google Scholar 

  23. Zhao Q, Sun Z, Guo B (2016) Material removal mechanism in ultrasonic vibration assisted polishing of micro cylindrical surface on SiC. Int J Mach Tool Manu 103:28–39. https://doi.org/10.1016/j.ijmachtools.2016.01.003

    Article  Google Scholar 

  24. Yu T, Guo X, Wang Z, Xu P, Zhao J (2019) Effects of the ultrasonic vibration field on polishing process of nickel-based alloy Inconel718. J Mater Process Tech 273:116–228. https://doi.org/10.1016/j.jmatprotec.2019.05.009

    Article  Google Scholar 

  25. Luo S, Zhu D, Hua L, Qian D, Yan S, Yu F (2016) Effects of process parameters on deformation and temperature uniformity of forged Ti-6Al-4V turbine blade. J Mater Eng Perform 25(11):1–13. https://doi.org/10.1007/s11665-016-2320-0

    Article  Google Scholar 

  26. Kanesund J, Brodin H, Johansson S (2020) High temperature corrosion influence on deformation and damage mechanisms in turbine blades made of IN-792 during service. Eng Fail Anal 110:104388. https://doi.org/10.1016/j.engfailanal.2020.104388

    Article  Google Scholar 

  27. Liu Z, Wong T, Huang W, Sridhar N, Wang S (2017) Effect of surface polishing treatment on the fatigue performance of shot-peened Ti-6Al-4V alloy. Acta Metall Sin-Eng 30(7):1–11. https://doi.org/10.1007/s40195-017-0555-x

    Article  Google Scholar 

  28. Pramanik A, Littlefair G (2015) Machining of titanium alloy (Ti-6Al-4V) theory to application. Mach Sci Technol 19:1–49. https://doi.org/10.1080/10910344.2014.991031

    Article  Google Scholar 

  29. Yu T, Shi Y, He X, Kang C, Deng B, Song S (2016) Optimization of parameter ranges for composite tape winding process based on sensitivity analysis. Appl Compos Mater 19(1):1–49. https://doi.org/10.1007/s10443-016-9553-9

    Article  Google Scholar 

  30. Wang L, Diskin B, Biedron R, Nielsen E, Bauchau O (2019) High-fidelity multidisciplinary sensitivity analysis and design optimization for rotorcraft applications. AIAA J 57(8):1–15. https://doi.org/10.2514/1.J056587

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to acknowledge the financial support provided by the National Science and Technology Major Project (Grant No.2017-VII-0002-0095) and the Natural Science Basic Research Program of Shaanxi (Program No. 2022JQ-503).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Danni Lu, Kaining Shi, Yaoyao Shi, Zhaoqing Zhang, Yihui Song, Zhe He & Yuchang Fan

  2. Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi’an, Shaanxi, 710072, China

    Danni Lu, Kaining Shi, Yaoyao Shi, Zhaoqing Zhang, Yihui Song, Zhe He & Yuchang Fan

  3. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (Northwestern Polytechnical University), Ministry of Education, Xi’an, 710072, China

    Danni Lu, Kaining Shi, Yaoyao Shi, Zhaoqing Zhang, Yihui Song, Zhe He & Yuchang Fan

  4. Xi’an Aeronautical University, Xi’an 710077, Shaanxi, China

    Zhen Chen

Authors
  1. Danni Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kaining Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yaoyao Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhaoqing Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yihui Song
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Zhe He
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Yuchang Fan
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Zhen Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Danni Lu (First Author): conceptualization, methodology, investigation, writing-original draft, Visualization. Kaining Shi (Corresponding Author): supervision, methodology, project administration. Yaoyao Shi: resources, funding acquisition. Zhaoqing Zhang: writing, methodology. Yihui Song:Methodology. Zhe He:Writing-review & editing. Yuchang Fan:investigation, writing-original draft. Chen Zhen: Investigation, Writing-review & editing.

Corresponding author

Correspondence to Kaining Shi.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lu, D., Shi, K., Shi, Y. et al. Machining behavior and experimental investigation of ultrasonic vibration assisted belt flapwheel flexible polishing. Int J Adv Manuf Technol 132, 1251–1265 (2024). https://doi.org/10.1007/s00170-024-13380-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-024-13380-7

Keywords

Search

Navigation