Sensitivity of surface roughness to flexible polishing parameters of abrasive cloth wheel and their optimal intervals

High-speed rotating abrasive cloth wheel is a highly flexible material that can be used to polish aviation engine blades. In this study, sensitivity and relative sensitivity to processing parameters were described on the basis of an empirical model of surface roughness to control the polishing of rough surfaces with abrasive cloth wheels. A mathematical model of the sensitivity and relative sensitivity of surface roughness to processing parameters was also established on the basis of an orthogonal test of polishing TC4 blade workpieces by utilizing abrasive cloth wheels. The sensitivity of the analytical method for processing parameter interval was examined, and the division principle and approach for the stable and unstable ranges of processing parameters were proposed. The influence curve of polishing parameters on surface roughness was obtained by combining the analyzed ranges in the orthogonal test. The optimization of processing parameter interval was also presented to identify the optimal intervals of surface-roughness-oriented polishing parameters of abrasive cloth wheels. The polishing test based on an aviation engine blade confirmed that the optimal intervals of the parameters were reliable. This research provides a basis for theoretical studies and tests to evaluate blade polishing technique with abrasive cloth wheels and surface roughness control.