The paper focuses on the study of the finishing stage of compressor blade manufacturing and the possibilities of vibro-abrasive polishing (VAP) as high-performance automated finishing of blades produced by High-Speed Milling (HSM), as well as the research of the surface condition and the influence of polishing on the blade fatigue resistance. Blades are the most heavily loaded components in modern gas turbine engines (GTE). Improving the surface quality and surface layer properties of these critical GTE parts is an important engineering challenge. After HSM, milling cutter traces remain on the processed blade surfaces, their geometry depending on cutting modes. Removing these traces and the defective layer from blade surfaces by manual polishing has several disadvantages and low productivity. The finishing of the investigated blades (of titanium alloy VT8 and nickel alloy EP718) was carried out manually on a grinding and polishing machine and in automatic mode on a vibro-abrasive machine. After finishing processing, the surface roughness, degree of hardening, residual stresses, and fatigue limit of the blades were measured. The best results were achieved after 5 h of VAP: roughness reduced from 0.36 μm to 0.18 μm; the degree of surface hardening improved from 7 to 20%; residual stress transitioned from tensile (+70 MPa) to compressive one (−450 MPa); as a result, blade fatigue resistance increased by 15%. The using of VAP after HSM allowed an increase in finishing productivity from 6 to 25 times depending on the blade size and number of blades in the set.

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Improving Finishing of Aero-Engine Compressor Blades with Vibro-Abrasive Polishing

  • Natalia Honchar,
  • Pavlo Tryshyn,
  • Eduard Kondratiuk,
  • Mykhailo Hrebennikov,
  • Natalia Myronova

摘要

The paper focuses on the study of the finishing stage of compressor blade manufacturing and the possibilities of vibro-abrasive polishing (VAP) as high-performance automated finishing of blades produced by High-Speed Milling (HSM), as well as the research of the surface condition and the influence of polishing on the blade fatigue resistance. Blades are the most heavily loaded components in modern gas turbine engines (GTE). Improving the surface quality and surface layer properties of these critical GTE parts is an important engineering challenge. After HSM, milling cutter traces remain on the processed blade surfaces, their geometry depending on cutting modes. Removing these traces and the defective layer from blade surfaces by manual polishing has several disadvantages and low productivity. The finishing of the investigated blades (of titanium alloy VT8 and nickel alloy EP718) was carried out manually on a grinding and polishing machine and in automatic mode on a vibro-abrasive machine. After finishing processing, the surface roughness, degree of hardening, residual stresses, and fatigue limit of the blades were measured. The best results were achieved after 5 h of VAP: roughness reduced from 0.36 μm to 0.18 μm; the degree of surface hardening improved from 7 to 20%; residual stress transitioned from tensile (+70 MPa) to compressive one (−450 MPa); as a result, blade fatigue resistance increased by 15%. The using of VAP after HSM allowed an increase in finishing productivity from 6 to 25 times depending on the blade size and number of blades in the set.