Allowance Determining for Wear-Resistant Gas-Thermal Coatings Grinding on Figurine-Shaped Surfaces of Aircraft Engines Parts

Mechanical Engineering and Machine Science


Аuthors

Rogov N. V.

Baumann Moscow State Technical University, 105005, Moscow, 2nd Baumanskaya St., b. 5, c. 1

e-mail: nikolayrogov_24@mail.ru

Abstract

The article deals with the technique development for the optimal grinding allowance determining of wear-resistant coatings applied by the high-speed flame spraying on the internal composite surfaces of the aircraft parts. The main attention is being paid to the working surfaces of the rotary piston engine stator, which geometry is set by the epitrochoid. The shape deviations and uneven microhardness after grinding reduce the engine reliability, especially when part of the single-engine unmanned aerial vehicles.
The author analyzed the two well-known approaches to the allowances assigning. They are the computational-and-analytical approach and the one based on technological heredity. It was found that these approaches are insufficient when processing the coatings formed by the high-speed flame spraying on complex surfaces, since they do not account for the patterns of microhardness distribution over the coating depth, the thermal force action from the cutting tool and the defective surface layer of the coating.
The article formulates a model of the microhardness changing by the coating thickness prior and after grinding. Three zones are marked out prior to grinding, namely reduced and stable microhardness, as well as a transition layer. After grinding, a decrease in microhardness is being observed in the surface layer with a depth of Q. This zone is modeled discretely as a function of cutting depth and grinding parameters (speed, feed, abrasive disc grit).
An optimization objective function, which reflects the integral difference in microhardness between the sections with the minimum and maximum initial coating thickness, is proposed. The optimal allowance is being defined as the point of this function minimum, which ensures uniform wear and increases the part reliability.
The author developed a technique for the optimal allowance computing in the form of a block diagram, which includes the coating profile plotting, the microhardness reduction zones determining, grinding modes selecting, modeling, and the target function construction and optimization. The said technique may be applied in the automated systems for technological processes designing for parts manufacturing at the aircraft engines production.
The practical significance consists in the grinding precision increasing, the main processing time reducing, as well as the time for the cutting modes debugging. The model validation requires accelerated tests to the wear resistance determining, as well as semi-natural tests of the stator as a part of the engine.

Keywords:

optimization of grinding allowance, grinding of thermal spray coatings, high-speed flame spraying, stator of a rotary piston engine, internal composite surfaces, microhardness of a wear-resistant coating, microhardness distribution over coating depth, uniformity of wear of a thermal spray coating, reliability of the stator of a rotary piston engine with a wear-resistant thermal spray coating

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