Research On Contact Theory Of Abrasive Belt Grinding With Metal Rubber

High-performance complex profile components such as aero-engine blades have complex profile,weak rigidity,and its material is difficult to machine,the machining quality has an important influence on service performance and service life of the machine.Abrasive belt grinding has been successfully applied to the field of precision machining of high-performance complex surface components such as aero-engine blades because of its elastic processing characteristics,it has a better fitting effect on the smooth transition of weakly rigid and complex profile contours.However,the elastic properties of abrasive belt grinding causes the nonlinearity and uncertainty of the contact status between abrasive belt with workpiece surface.In addition,since the contact wheel in the abrasive system is easy to wear,it will interferes the contact status,which is disadvantageous for achieving precise control of the blade profile and the quality of machined surface.Metal rubber is a new type of elastic material,compared with ordinary rubber material,it has higher load-carrying capacity,fatigue resistance and high reliability.Therefore,this paper uses metal rubber replace ordinary rubber material to manufacture the contact wheel,and research the flexible contact status of abrasive belt grinding.On this basis,the influence law of the contact wheel parameters on the contact state of abrasive belt grinding is further studied.The main content is as follows:(1)Analyze the main problems in the manufacture of contact wheel with metal rubber;Carry out the experiment of wear resistance and compress test of contact wheel with metal rubber,study the wear law of metal rubber contact wheel and determine the performance parameters of metal rubber material;Furthermore,through the grinding comparison experiment between the metal rubber contact wheel and the ordinary rubber contact wheel,the influence on the wear of abrasive belt,the material remove and the quality of the roughness of machined surface are analyzed.(2)The geometric model of abrasive belt grinding contact status is established,and the influence law of grinding pressure,contact wheel radius and workpiece radius of curvature on the abrasive contact status is derived based on Hertz contact theory.Modeling and simulation analysis of abrasive belt grinding contact status of complex profile aero-engine blades with ANSYS;The abrasive belt grinding experiment is carried out on a certain type of aero-engine blades,and the change of contact status during the grinding process of complex surface and its influence on the material removal and the roughness of machined surface are further studied.(3)The contact status of abrasive belt grinding with different diameter,elastic layer thickness,width and elastic modulus contact wheel is simulated to study the influence of above parameters on the contact status,and the experiments with different elastic modulus contact wheel is carried out.On this basis,the abrasive belt grinding experiment for titanium alloy sample based on metal rubber contact wheel is carried out,and the influence of grinding process parameters on material removal and the roughness of machined surface is studied.