CN101209538B - 确定初始抛光参数的方法 - Google Patents

确定初始抛光参数的方法 Download PDF

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CN101209538B
CN101209538B CN200710307262.2A CN200710307262A CN101209538B CN 101209538 B CN101209538 B CN 101209538B CN 200710307262 A CN200710307262 A CN 200710307262A CN 101209538 B CN101209538 B CN 101209538B
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polishing
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CN101209538A (zh
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A·卢纳
M·布伦克
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General Electric Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B39/00—Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B39/00—Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor
    • B24B39/003—Burnishing machines or devices, i.e. requiring pressure members for compacting the surface zone; Accessories therefor the working tool being composed of a plurality of working rolls or balls
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/55—Hardenability tests, e.g. end-quench tests
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/08—Modifying the physical properties of iron or steel by deformation by cold working of the surface by burnishing or the like
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
    • C22F1/18—High-melting or refractory metals or alloys based thereon
    • C22F1/183—High-melting or refractory metals or alloys based thereon of titanium or alloys based thereon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/47—Burnishing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/47—Burnishing
    • Y10T29/471—Burnishing of water laid fibrous article [e.g., paper]
    • Y10T29/473—Heated burnishing member
    • Y10T29/474—Burnishing tool reciprocates across work surface
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49764—Method of mechanical manufacture with testing or indicating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49764—Method of mechanical manufacture with testing or indicating
    • Y10T29/49771—Quantitative measuring or gauging
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49764—Method of mechanical manufacture with testing or indicating
    • Y10T29/49771—Quantitative measuring or gauging
    • Y10T29/49776—Pressure, force, or weight determining
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49764—Method of mechanical manufacture with testing or indicating
    • Y10T29/49778—Method of mechanical manufacture with testing or indicating with aligning, guiding, or instruction

Abstract

一种确定抛光加工参数的方法，包括：用滚动抛光单元(11)在材料样品(13)的一个选定表面(12)上抛光至少两个节段(14)，所述节段(14)具有共同的宽度(W)，并按照预设的重叠值(OV)彼此重叠；测量所述表面(12)的结果硬度；并根据所述测得的硬度值，为后续工件(WP)上的抛光加工选择工作重叠值(OV)。

Description

确定初始抛光参数的方法
技术领域
本发明大体上涉及制造抗疲劳及耐损伤部件的方法，更特别地说，本发明涉及一种设置抛光(burnishing)处理加工参数的方法。
背景技术
多种金属材料、陶瓷材料以及复合材料的部件，例如气体涡轮引擎风扇和压缩机叶片，均易产生由疲劳和损伤(例如，来自外部物体的撞击)导致的破裂。所述损伤降低了零件的寿命，要求维修或更换。抛光的主要目的是将残余应力分散在表面上以获得实质性的好处，如抗疲劳和抗腐蚀，并预防裂缝形成和扩散。对于这些好处，航空航天业最关注的是提高疲劳寿命及抗疲劳应力的能力。众所周知，要保护部件防止裂缝扩散，需要通过产生其中的压应力来实现。产生这些压应力的办法包括喷丸处理，激光喷丸处理(LSP)，夹紧冷作硬化(pinch peening)，以及低塑性抛光(LPB)。这些方法典型情况下通过在需要保护防止裂缝扩散的区域上施加残余压应力的“补丁”来使用。
典型的抛光设备包括滚动抛光单元，例如圆柱或球体单元，这些圆柱或球体单元通过机械或液压的方式以选定的抛光压力加载在工件上，并经过一系列的行程或节段横跨零件表面。残余应力的数量是一系列参数的一个函数，其中影响最大的是抛光压力和抛光行程的重叠(overlap)程度。由于疲劳测试的高成本，在假定抛光压力和重叠程度范围较宽的情况下，这些参数的初始选择过程可证明是很昂贵的。
在现有技术中，初始压力和重叠的选择或者随机执行，或者通过试验和误差。试验和误差方法不仅昂贵，而且耗时。
此外，使用从某个特殊应用得到的参数可能对于另一个应用不会得到相同的结果。例如，在相同的条件下抛光两个相同材料制成，但横截面厚度不同的薄盘，将会产生不同程度的，深达临界厚度的重叠，以及由此而来的在疲劳测试中的不同表现。所述临界厚度是针对一种给定材料的厚度，在这个厚度上，如果所有其它参数都保持恒定，重叠程度将在这个值之上或超出这个值而保持恒定。
发明内容
本发明将上述现有技术的缺点和其它缺点一起做了陈述，根据一个实施例，本发明提供了一种确认用于抛光加工的参数确认方法，包括：使用滚动抛光单元在材料样品的选定表面上抛光至少两个节段(segment)，所述节段具有共同的宽度，并以预选的重叠值相互重叠；测量表面的结果硬度；以及根据所测得的硬度，对工件上的后续的抛光加工选择工作重叠值。
附图说明
本发明通过参考如下与附图相关联的具体实施方式描述而可以得到最好的理解，其中：
图1是抛光加工的一种施加样式的顶部示意图；
图2A是显示零重叠状态的抛光路径的顶部示意图；
图2B是显示负重叠状态的抛光路径的顶部示意图；
图2C是显示完全重叠状态的抛光路径的顶部示意图。
零部件清单
10    抛光样式
12    表面
14    节段
16    侧节段
F    进给距离
P    路径
W    宽度
具体实施方式
参考附图，其中在所有不同的视图中，相同的标号代表相同的单元，图1显示了在要处理的工件“WP”的样品13的一个表面12上重叠的一种普遍的抛光样式10。用这种方式处理的工件WP的非限制性样品包括压缩机叶片和定子叶片，风扇叶片，涡轮机叶片，轴以及转子，静止框架，执行机构硬件以及类似工件。此类工件WP可由金属合金、陶瓷或复合材料(例如碳纤维合成物)制成。这种抛光样式10典型情况下通过使用一种已知类型的抛光装置来进行施加，所述抛光装置包括滚动抛光单元11，该单元由一台多轴数字或计算机控制的控制器以液压或机械方式加载在表面12上。
如图所示，抛光样式10包括多个节段14，所述节段按一系列沿限定了节段中心线的路径“P”的S形拐弯排列，并由外侧的节段16连接。所述节段14分开一段进给距离“F”(也称“跨越距离”或“偏移”)，该进给距离“F”是中心线路径P的相邻两条边线之间的距离。为适合某个特定应用，可使用不同的路径。为了安装、编程及测量的方便性，路径P最通常情况下包括一些直线节段或行程的组合。
节段14(也称“印迹”)的宽度“W”是工件WP的材料和厚度，以及所施加的抛光压力和所使用的抛光单元11的尺寸和特性的一个函数。这种进给距离F和印迹W之间的关系决定了节段14之间的重叠程度。特别地，重叠值“OV”可在数学上作为一个百分数表示：OV＝[(W-F)/W]×100。
如果节段14是在进给F等于印迹W的情况下并排地抛光的，那么它们彼此将不会重叠(图2A)。这被认为是一个0％重叠值OV，如图2A所示。如果进给F大于该0％重叠值OV，则在相邻印迹W之间将会有一个间隔。这被认为是一个负重叠值OV，如图2B所示。最后，当进给F等于印迹W，节段14大体上彼此重叠地被抛光，且它们被认为处于100％重叠值OV。这种情况如图2C所示。
按如下过程初始化抛光加工的初始参数。首先，选择具有已知材料成分和厚度的材料样品13。在工件WP的样品13上抛光出测试节段14，并对这些节段14的宽度进行测量，以确定在选定抛光压力下的抛光印迹W。这一印迹值限定了如上所述的0％重叠值OV。
接下来，使用不同定义的重叠值，在工件WP的样品13的表面12的选定区域上，以从0％到100％之间的重叠值OV，抛光出补丁，并测量硬度。接着对硬度测量值进行分析来确定所需的重叠值OV。所使用的不同定义的重叠值OV可随机确定，例如通过使用重叠的相等增量，或使用实验设计(DOE)或其它统计方法。通常，较高的硬度值对应较大的抗疲劳能力，并且是所需的。一旦进行了硬度测量，则对应所需硬度值(例如最大硬度)的重叠值OV被用作处理后续工件WP的工作重叠值OV。
范例
上述的参数设置过程被用于Ti-6-4合金平板，以找出气体涡轮机引擎压缩机叶片疲劳测试的初始加工参数。在印迹W约为0.4178mm(16.45密耳)的钛样品13上观察到下列一般的结果：重叠值OV在约90％到100％之间(高重叠范围)的硬度结果通常低于低重叠设置值。高重叠设置值在样品13上还会产生更大的变形。这暗示在高重叠设置值上材料样品13在肉眼可见的比例可塑性变形。另一方面，在约50％重叠值OV或更低值(低重叠范围)上当重叠设置值减小时硬度结果通常也下降。通过对抛光印迹W和硬度结果的分析，为后续压缩机叶片的抛光选择初始压力和增量进给F。对抛光后叶片的检测显示，叶片的抗疲劳应力的能力在测试条件下比其原有值提高了约200％。
上述过程快捷而便宜。它允许使用便宜的材料样品而不是昂贵的抛光产品。它还采用了便宜而快速的测试(长度测量和硬度测量)来在进行任何疲劳测试之前缩小参数的选择范围。
以上描述了一种用于抛光加工参数设置的方法。虽然所描述的是本发明的特定实施例，但很明显，本领域的熟练技术人员可在不背离本发明的精神和范围的前提下进行各种修改。因此，以上关于本发明的优选实施例以及实践本发明的最优模式的描述仅仅是出于说明目的而提供的，并非出于任何限制的目的，本发明由权利要求所限定。

Claims (7)

1.一种确定抛光加工参数的方法，包括：
(a)使用滚动抛光单元(11)在材料样品(13)的选定表面(12)上抛光至少两个节段(14)，所述节段(14)具有共同的宽度(W)，并且按照预设的重叠值(OV)而彼此重叠；
(b)测量所述表面(12)的结果硬度；并
(c)根据所述测得的硬度值，为在后续工件(WP)上的抛光加工来选择工作重叠值(OV)。
2.根据权利要求1所述的方法，其特征在于，所述共同的宽度(W)通过如下步骤确定：
(a)在所述选定表面(12)上抛光测试节段(14)；并
(b)测量所述节段(14)的宽度(W)。
3.根据权利要求1所述的方法，还包括，用一定范围的重叠值(OV)来重复所述步骤(a)和(b)，来生成多个硬度测量值。
4.根据权利要求3所述的方法，其特征在于，所述重叠值(OV)的范围为50％到90％。
5.根据权利要求3所述的方法，还包括，选择对应于所述多个硬度测量值中最大硬度测量值的工作重叠值(OV)。
6.根据权利要求3所述的方法，还包括，将每个所述测得的硬度值和所述材料样品(13)的所测得的抗疲劳值相关联对应起来。
7.根据权利要求1所述的方法，还包括，用所述选定的工作重叠值(OV)在工件(WP)上进行抛光加工。
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US20080160891A1 (en) 2008-07-03
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US8079120B2 (en) 2011-12-20
SG144088A1 (en) 2008-07-29
DE602007005761D1 (de) 2010-05-20
EP1938926A1 (en) 2008-07-02
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