航空发动机整体叶盘磁力研磨光整实验

磁力研磨工艺抛光整体叶盘时,工件与磁极干涉严重,用径向磁极代替轴向磁极加工可有效避免干涉,但研磨压力小、研磨效率低.通过对磁力研磨径向磁极加工机理和单个研磨粒子的微观受力情况详细分析得到:提高磁场强度变化率可有效增大磁力研磨效率.经有限元模拟分析发现磁极表面沿轴线方向开矩形槽可使磁场强度变化率提高.对镍基高温合金材质整体叶盘进行磁力研磨实验,并对实验数据分析研究得出:以径向磁极为工具的磁力研磨法可实现对整体叶盘的无干涉加工,磁极开矩形槽后磁力研磨效率可提高31%,叶盘表面粗糙度值由研磨前的1.2μm降至0.18μm,验证了磁力研磨工艺对高效、高质量实现整体叶盘表面光整加工的可行性. 

Experiment of surface finishing on aero-engine blisk by magnetic abrasive finishing

When finishing the blisk with the process of magnetic abrasive finishing, the interference between the workpiece and the magnetic pole is serious. Machining with radial magnetic pole instead of axial magnetic pole can effectively avoid interference, but the finishing pressure and the finishing efficiency are low. By analyzing the mechanism of radial magnetic abrasive finishing and the microscopic forces carried by the single magnetic abrasive particle, it derived that increasing the variance ratio of magnetic field intensity could significantly increase the magnetic abrasive finishing efficiency. With finite element simulation and analysis, it showed that slotting rectangular grooves along the axis direction on the surface of magnetic pole could improve the variance ratio of the magnetic field intensity. Through the magnetic abrasive finishing experiment to nickel-based superalloy blisk and analyzing the experimental data, it was concluded that the magnetic abrasive finishing with radial magnetic pole as the tool can realize finishing the blisk without interference, the magnetic abrasive finishing efficiency can be increased by 31% after the slotting rectangular grooves on the magnetic pole. The surface roughness value of the blisk was reduced from 1.2μm to 0.18μm. It verified the feasibility that the magnetic abrasive finishing can realize finishing the blisk surface with high efficiency and quality.