Analysis of vibration from low-rigidity contact in belt grinding of blisk blade

A blisk is one of the key parts of an aero-engine, whose surface processing quality directly affects aero-engine performance. Different degrees of vibration occur during the process of new open belt grinding which seriously affect the precision of the dimensions and the surface quality of the entire blade profile. With the aim of addressing this problem, this study constructed a physical model of blisk belt grinding, analysed the low-rigidity characteristics of the grinding system, and researched the vibratory mechanism of the blisk belt grinding system based on a dynamic analysis method. In addition, the factors affecting the stability of the grinding process and the stability conditions of the grinding were considered. Then, the belt grinding process of a blade surface was simulated through a numerical method. The technological parameters were quantified for different conditions of the blisk belt grinding vibration. The optimal combination of process parameters was obtained. Finally, the optimised process parameters were validated experimentally. The research demonstrates that vibration from blisk belt grinding is related to the process parameters as follows, in the order of the greatest influence: the grinding pressure, belt velocity, feed speed, and contact wheel hardness. After optimisation, the cross-sectional profile is 0.031–0.041 mm and the surface roughness is 0.1–0.2 μm; the surface is smoother and has better consistency.