Equivalent self-adaptive belt grinding for the real-R edge of an aero-engine precision-forged blade

Because of the special characteristics of aero-engine precision-forged blade edges such as heat-resistant and high-strength materials, the unequal distribution and small removal allowance, and easy deformation in processing, edge profile shape errors are easily caused by using conventional processing methods. These errors include chamfered, sharp, flat, and obtuse edges and cervical part shrinkage, so the real-R shape of the edge is difficult to guarantee, and the aero-engine air dynamic performance is seriously affected. The purpose of this research is to improve the dimensional precision, profile shape errors, and surface quality of the real-R edge of the precision-forged blade. With these aims, the method of equivalent self-adaptive belt grinding (ESBG) using a cubic boron nitride (CBN) belt is developed in this study. First, the grinding characteristics and process planning to the blade real-R edge are analyzed. The methodologies of equivalent belt grinding (EBG) and ESBG using a CBN belt are then illustrated, the control equation for EBG is established, and the method of force adaptive control is introduced. Finally, the ESBG method using the CBN belt is verified by experimental investigation of the aero-engine precision-forged blade and comparison with manual and EBG methods. The experimental results showed that the ESBG method using the CBN belt achieved the requirements of the aero-engine precision-forged blade real-R edge. It was verified that the method of ESBG using the CBN belt has the advantages of real-R shape dimensional precision and surface quality for the blade edge compared with the conventional method.