CN 41-1243/TG ISSN 1006-852X
CN
Advanced Search+
Volume 45 Issue 4
Aug.  2025
Turn off MathJax
Article Contents
Article Navigation >  Diamond & Abrasives Engineering  > 2025  >  45(4): 534-541
LI Mingcong, TIAN Peisen, HUANG Yun, YAN Shengbo, ZOU Lai, WANG Wenxi. Design and performance of compliant grinding tools for blade root smooth grinding[J]. Diamond & Abrasives Engineering, 2025, 45(4): 534-541. doi: 10.13394/j.cnki.jgszz.2024.0059
Citation: LI Mingcong, TIAN Peisen, HUANG Yun, YAN Shengbo, ZOU Lai, WANG Wenxi. Design and performance of compliant grinding tools for blade root smooth grinding[J]. Diamond & Abrasives Engineering, 2025, 45(4): 534-541. doi: 10.13394/j.cnki.jgszz.2024.0059
shu

Design and performance of compliant grinding tools for blade root smooth grinding

doi: 10.13394/j.cnki.jgszz.2024.0059
  • 1.

    State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China

  • 2.

    School of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin 150001, China

More Information
  • Received Date: 2024-03-29
  • Accepted Date: 2024-08-14
  • Rev Recd Date: 2024-07-24
    Abstract
  •   Objectives  The difficulty in machining complex structural components such as aircraft engine blade roots is a common problem in the precision machining industry, and the stability of grinding tool performance is crucial for achieving automated machining. In a narrow processing space, due to the poor thermal stability of flexible materials themselves, the accumulation of grinding heat can reduce the service life and grinding performance of the grinding tool, becoming a key factor in the decrease of precision in automated processing of complex structural components. Therefore, an enhanced blade heat conduction structure is introduced into the ball-end grinding tool to improve the heat conduction performance of the grinding tool and increase its service life and application performance.  Methods  Through fluid dynamics simulation, the influences of the rotation direction, the rotation speed of the grinding tool, and the flow rate of external cold air on the flow field, temperature field, pressure field of the grinding tool are studied. A flexible grinding tool substrate with a complex internal structure is prepared using multi-layer melt spraying technology, and an adhesive grinding tool with a sandwich structure is designed to ensure precise and tight adhesion between the abrasive layer and the ball-head grinding tool substrate. The processing trajectory programmed by industrial robots is adopted to conduct an automated processing of titanium alloy plates for 200 s. The grinding performance differences between the designed grinding tools and the traditional structural grinding tools are compared through indicators such as grinding temperature, surface roughness, and cumulative material removal depth. Meanwhile, through the analysis of the microscopic morphology of the grinding surface of titanium alloy and the wear of the grinding tool, the internal mechanism of the designed grinding tool in improving the continuous grinding performance is clarified.  Results  When the grinding tool with an enhanced heat transfer mechanism rotates counterclockwise, the external fluid is introduced into the inner cavity of the grinding tool, forming a significant vortex. Meanwhile, the blade structure helps enhance the convection of gas in the inner cavity to achieve heat exchange. Moreover, the external fluid is blown at high speed towards the cavity near the outer side of the inner wall, forming a high-pressure area, which further promotes heat transfer. The grinding tools with an internal blade structure have a stronger cooling capacity at higher rotational speeds, and the surface temperature is lower than 170 ℃ when the rotational speed is 14000 r/min. However, the cooling effect of the grinding tools with traditional structures is relatively weak as the rotational speed increases. When the rotational speed is 14000 r/min, the surface temperature is still higher than 180 ℃. As the flow of external cold air increases, more cold air is drawn into the interior of the grinding tool blade structure, bringing a stronger heat transfer effect, improving the cooling utilization rate and reducing the temperature of the grinding tool. The grinding temperature of traditional solid-structured grinding tools is the highest, exceeding 140 ℃ between 55 and 100 s. The strong accumulation of local grinding heat causes the flexible material to melt and adhere to the surface of the grinding tool, hindering its material removal. Therefore, the material removal capacity of traditional solid-structured grinding tools drops sharply after 140 s. In addition, there are significant fluctuations in the surface roughness of the workpiece grinding. The annular adhesion phenomena are observed on the surface of traditional structural grinding tools. The main failure mode of the internal blade structure grinding tool is the stripping of the abrasive layer. Its enhanced heat conduction structure can effectively achieve heat exchange between cold air and local high temperature in the grinding area, thereby alleviating the adhesion of the flexible substrate.  Conclusions  The formation, propagation and dissipation of vortices inside the grinding tool promote the improvement of heat conduction efficiency, thereby enabling the designed flexible grinding tool to achieve higher heat conduction performance and grinding effect. In addition, as the grinding speed increases, the temperature uniformity on the surface and inside the grinding tool is improved. The grinding tools with an internal blade structure maintain a relatively stable grinding temperature and material removal capacity during continuous grinding, as well as good surface quality of the workpiece.

     

    • FullText(HTML)
  • loading
    • References(19)
  • [1]
    段继豪, 安佳乐, 吴卓繁, 等. 航发叶片砂碟磨削接触特性及材料去除机理 [J]. 机械工程学报, 2023, 59(17): 349-360. doi: 10.3901/JME.2023.17.349

    DUAN Jihao, AN Jiale, WU Zhuofan, et al. Contact characteristics and material removal mechanism of abrasive disc grinding of aero-engine blade [J]. Journal of Mechanical Engineering, 2023, 59(17): 349-360. doi: 10.3901/JME.2023.17.349
    [2]
    LIU M, LI C, YANG M, et al. Mechanism and enhanced grindability of cryogenic air combined with biolubricant grinding titanium alloy[J]. Tribology International, 2023, 187: 108704.
    [3]
    LI M, HUANG Y, WANG W, et al. A novel 3D printed compliant ball-end grinding tool with crystal structure: Feasibility and performance analysis [J]. Materials & Design, 2024, 237: 112591. doi: 10.1016/j.matdes.2023.112591
    [4]
    PUŠAVEC F, GRGURAŠ D, KOCH M, et al. Cooling capability of liquid nitrogen and carbon dioxide in cryogenic milling [J]. CIRP Annals, 2019, 68(1): 73-76. doi: 10.1016/j.cirp.2019.03.016
    [5]
    钱宁, 徐九华, 傅玉灿, 等. 面向绿色高效磨削的振荡热管砂轮磨削温度与强化传热分析 [J]. 机械工程学报, 2022, 58(15): 105-120. doi: 10.3901/JME.2022.15.105

    QIAN Ning, XU Jiuhua, FU Yucan, et al. Investigation on grinding temperature and heat transfer performance of oscillating grinding wheel for high-efficient green grinding [J]. Journal of Mechanical Engineering, 2022, 58(15): 105-120. doi: 10.3901/JME.2022.15.105
    [6]
    XIANG X, YU J, MEI C, et al. An internal cooling grinding wheel: From design to application [J]. Chinese Journal of Aeronautics, 2023, 36(11): 465-482. doi: 10.1016/j.cja.2023.02.024
    [7]
    GHEYNANI A R, AKBARI O A, ZARRINGHALAM M, et al. Investigating the effect of nanoparticles diameter on turbulent flow and heat transfer properties of non-Newtonian carboxymethyl cellulose/CuO fluid in a microtube [J]. International Journal of Numerical Methods for Heat & Fluid Flow, 2018, 29(5): 1699-1723. doi: 10.1108/hff-07-2018-0368
    [8]
    GHETAN S, RAO P V. Comparison between sustainable cryogenic techniques and nano-MQL cooling mode in turning of nickel-based alloy [J]. Journal of Cleaner Production, 2019, 231: 1036-1049. doi: 10.1016/j.jclepro.2019.05.196
    [9]
    REDDY P P, GHOSH A. Some critical issues in cryo-grinding by a vitrified bonded alumina wheel using liquid nitrogen jet [J]. Journal of Materials Processing Technology, 2016, 229: 329-337. doi: 10.1016/j.jmatprotec.2015.09.040
    [10]
    QIAN N, JIANG F, MARENGO M, et al. Thermal performance of a radial-rotating oscillating heat pipe and its application in grinding processes with enhanced heat transfer [J]. Applied Thermal Engineering, 2023, 233: 121213. doi: 10.1016/j.applthermaleng.2023.121213
    [11]
    TONG J, PENG R, SONG Q. A Cu-based ceramic porous abrasive ring with phyllotactic pattern in internal cooling grinding of Inconel 718 [J]. Journal of Materials Processing Technology, 2023, 315: 117890. doi: 10.1016/j.jmatprotec.2023.117890
    [12]
    PENG R, TONG J, TANG X, et al. Application of a pressurized internal cooling method in grinding inconel 718: Modeling-simulation and testing-validation [J]. International Journal of Mechanical Sciences, 2021, 189: 105985. doi: 10.1016/j.ijmecsci.2020.105985
    [13]
    MIZUTANI T, SATAKE U, ENOMOTO T. A study on a cooling method for bone grinding using diamond bur for minimally invasive surgeries [J]. Precision Engineering, 2021, 70: 155-163. doi: 10.1016/j.precisioneng.2021.01.010
    [14]
    LAN J, ZHANG Z, LIANG X, et al. Experimental and numerical investigation on thermal performance of data center via fan-wall free cooling technology [J]. Applied Thermal Engineering, 2023, 228: 120467. doi: 10.1016/j.applthermaleng.2023.120467
    [15]
    PENG C C, CHEN T Y. A recursive low-pass filtering method for a commercial cooling fan tray parameter online estimation with measurement noise [J]. Measurement, 2022, 205: 112193. doi: 10.1016/j.measurement.2022.112193
    [16]
    GALLONI E, PARISI P, MARIGNETTI F, et al. CFD analyses of a radial fan for electric motor cooling [J]. Thermal Science and Engineering Progress, 2018, 8: 470-476. doi: 10.1016/j.tsep.2018.10.003
    [17]
    ZHONG X L, CHAN K C, FU S C, et al. Enhancement of piezoelectric fan cooling by geometrical arrangements [J]. International Journal of Heat and Mass Transfer, 2022, 199: 123479. doi: 10.1016/j.ijheatmasstransfer.2022.123479
    [18]
    AMER M. A novel bionic impeller for laptop cooling fan system [J]. Results in Engineering, 2023, 20: 101558. doi: 10.1016/j.rineng.2023.101558
    [19]
    CHOUDHARY M, MUKHERJEE S, KUMAR P. Analysis and optimization of geometry of 3D printer part cooling fan duct [J]. Materials Today: Proceedings, 2022, 50: 2482-2487. doi: 10.1016/j.matpr.2021.10.444
    • Relative Articles
    • Supplements(0)
    • Cited By
  • 加载中

Catalog

    通讯作者: 陈斌, bchen63@163.com
    • 1. 

      沈阳化工大学材料科学与工程学院 沈阳 110142

    1. 本站搜索
    2. 百度学术搜索
    3. 万方数据库搜索
    4. CNKI搜索

    Figures(14)  / Tables(1)

    Get Citation
    PDF
    XML

    Article Metrics

    Article views (39) PDF downloads(1) Cited by()
    Proportional views
    Related
    Website Copyright © Zhengzhou Research Institute for Abrasives and Grinding Co., Ltd.  豫ICP备05008669号
    Address：No. 121, Wutong Street, Hitech Zone, Zhengzhou  Postal Code：450001
    Phone:  0371-55983716
    Email Alerts RSS

    Supported by: Beijing Renhe Information Technology Co., Ltd.    

    /

    DownLoad:  Full-Size Img  PowerPoint
    Return
    Return