The abrasive processing process of turbine blades is relatively complex and covers multiple links. During the machining process, high-performance abrasive tools are often required to meet the high material and process requirements of the aerospace industry.The following is the general process for abrasive processing of turbine blades:
Step1: Design processing plan
According to the material, shape, size, and processing requirements of the turbine blade, determine the specific abrasive processing plan, including selecting the appropriate abrasive type (such as grinding wheel, abrasive belt, etc.), abrasive type (such as corundum, carbonized Silicon, diamond, etc.), particle size, hardness and other parameters, as well as formulating the processing route and operating steps 1.
Step2: Preparation
Blade inspection
Conduct a comprehensive inspection of the turbine blades to ensure that the blades have no cracks, defects, and other quality problems. At the same time, the initial size, shape and other parameters of the blades are measured as references during the processing
Equipment debugging
debug abrasive abrasive processing equipment, such as grinders, etc., to ensure the accuracy, stability and normal functions of the equipment. Including calibrating the coordinate axes of the machine tool (such as x, y, z axes), checking the rotation accuracy of the grinding head, the accuracy of the feed system, etc.
Preparation of tooling fixtures
According to the shape and processing requirements of the blades, design and prepare appropriate tooling fixtures to fix the blades to ensure that the position of the blades is accurate and stable during the processing process, and to facilitate processing operations.
Step3: Rough Machining
Use larger-grained, harder abrasives and abrasives at a higher feed speed and cutting depth to quickly remove most of the margin on the blade, making it close to the final shape, but leaving a certain amount of precision. Processing allowance. During the rough machining process, attention should be paid to controlling the grinding force and grinding temperature to avoid damage to the blades
Step4: Semi-finishing
On the basis of rough machining, medium-grained and hardened abrasives are used to appropriately reduce the feed speed and cutting depth to further improve the shape accuracy and surface quality of the blade, reduce surface roughness, and continue to remove a small amount of residual material.
Step5: Finishing
Use fine-grained, softer abrasives to perform fine processing at a lower feed speed and cutting depth to accurately achieve the final size, shape and surface quality requirements of the blade. During the finishing process, it may be necessary to use multiple passes and gradually reduce the machining allowance to ensure machining accuracy and surface quality
Step6: Polishing treatment (optional)
According to the use requirements and surface quality requirements of the blades, the blades can be polished to further reduce the surface roughness and improve the surface finish. Polishing can use polishing paste, polishing cloth and other abrasive tools, or special processes such as chemical polishing and electrolytic polishing
Step7: Quality inspection
Conduct a comprehensive quality inspection on the processed turbine blades, including inspection of dimensional accuracy, shape accuracy, surface roughness, surface quality (such as scratches, burns, and other defects). Commonly used detection methods include three-dimensional coordinate measuring instruments, optical microscopes, profilometers, surface roughness meters, etc. If quality problems are found, analyze the causes and take corresponding improvement measures, such as reprocessing, adjusting processing parameters, etc.
Step8: Cleaning and protection
Clean the inspected blades to remove impurities such as wear debris and oil on the surface, and then take appropriate protective measures, such as applying rust inhibitors, to prevent the blades from being corroded and damaged during storage and transportation.