目的 针对涡轮盘榫槽磨削加工复杂轮廓结构和成膜沸腾效应导致的冷却困难和局部烧伤问题,设计了一种空气自冷却砂轮成形磨削涡轮盘榫槽工艺。方法 应用单层电镀CBN砂轮,成形磨削线切割粗加工后的榫槽轮廓样件,采用切削力测量系统、热电偶、扫描电镜（SEM）、三维轮廓仪,研究了不同砂轮转速、工件进给速度、磨削深度下GH4169镍基高温合金涡轮盘榫槽样件的磨削力、磨削温度、表面形貌和表面粗糙度。结果 涡轮盘榫槽在不同磨削工艺参数下的切向磨削力Fy为22.6~35.7 N,径向磨削力Fx为38.4~48.1 N。榫槽峰顶区磨削温度最高,峰底区次之,过渡斜面磨削温度最低;榫槽不同区域的磨削温度控制在298.4 ℃以下,磨削表面未发生烧伤。榫槽磨削表面存在材料黏附、塑性流动和凹坑等形貌特征,过渡斜面的磨削沟痕浅而均匀,表面质量优于峰顶区和峰底区,表面粗糙度Ra可达0.6 μm。结论 空气自冷却砂轮能够实现涡轮盘榫槽的高效成形磨削,空气冷却效果良好,未发生榫槽表面烧伤。采用高转速、低进给、小切深的工艺参数能够显著提高涡轮盘榫槽磨削表面质量。
Abstract
The work aims to design an air self-cooling grinding wheel forming process for machining turbine disk slots to address the challenges of cooling difficulties and localized burning induced by the complex contour structure and film boiling effect. A single-layer electroplated CBN grinding wheel was employed for grinding of the slot contour on a GH4169 nickel- based superalloy turbine disk. To evaluate grinding performance under varying conditions, including grinding wheel rotational speed, workpiece feed rate, and grinding depth, measurements were conducted using a cutting force measurement system, thermocouples, scanning electron microscopy (SEM), and a three-dimensional profilometer to analyze grinding forces, temperature, surface morphology, and surface roughness. Results indicated that, the tangential grinding force Fy of the turbine disk slot under different grinding process parameters varied between 22.6 and 35.7 N, whereas the radial grinding force Fx ranged from 38.4 to 48.1 N. The highest grinding temperature occurred at the slot peak, followed by the slot bottom, with the lowest temperature observed on the transition slope. Grinding temperature across all regions remained below 298.4 ℃, and no surface burn marks were detected. The slot surface exhibited characteristic morphological features, including material adhesion, plastic flow, and pitting. On the transition slope, grinding scratches were shallow and uniformly distributed, resulting in superior surface quality compared with the peak and bottom regions, and the surface roughness achieved a value of Ra 0.6 μm. Conclusions indicate that the air self-cooling grinding wheel enables efficient profile grinding of turbine disk slots, demonstrating effective air-cooling performance with no occurrence of surface burn. By employing process parameters such as high wheel rotational speed, low workpiece feed rate, and small grinding depth, the surface quality of the ground turbine disk slots is significantly enhanced.
关键词
空气自冷却砂轮 /
涡轮盘榫槽 /
成形磨削 /
磨削温度 /
表面形貌
Key words
air self-cooling grinding wheel /
turbine disk slots /
profile grinding /
grinding temperature /
surface morphology
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基金
山西省基础研究计划（202203021222072, 202303021222114）; 山西省重点研发计划（202402050201009, 202402150301011）; 山西省科技成果转化专项项目（202304021301040）
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