Quantitative finite element analysis of microscopic surface formation for TC4 aeroengine blade polishing using single-grain method

Precision polishing of aeroengine blades involves a complex material removal process, primarily due to the presence of numerous abrasive grains bonded on the polishing tool. Therefore, understanding the surface formation mechanism at the microscale, as a result of a single abrasive grain’s interaction with the workpiece, is pivotal for deciphering the collective effect of numerous abrasive actions. Since conducting single-grain cutting experiments at the microscale presents significant challenges, the finite element method (FEM) is considered an effective method for revealing microscopic physical phenomena and conducting in-depth research on cutting mechanisms. In this research, the simplified single-grain scratch experiment was conducted first, and then, the adaptive remeshing technique in Abaqus was utilized to simulate the elastic and plastic deformation of the workpiece surface during the polishing process, supplementing the physical measurement results that are difficult to achieve in the scratch experiment. The single-grain scratch experiment results show that elastic deformation of the workpiece material persists throughout the grain cutting process, and the elastic deformation FEM simulation results show that the pure rubbing phase is confined to an extremely short length after the interference occurs between the grain and the workpiece. To delve into the plastic deformation of workpiece surface in FEM simulation, the material pile-up ratio was used, and the effect of polishing variables such as cutting speed, cutting depth, and grain size on microscopic surface creation was focused on. Among them, cutting depth and grain size significantly affect the surface creation of workpiece material. In addition, the microscopic plastic deformation when the abrasive grain cut-in and cut-out phases during the polishing process is different. The outcomes of these simulations are anticipated to inform future experimental strategies and foster advancements in the development of more efficient and precise aeroengine blade polishing techniques.