Process parameters optimization of flap wheel polishing in leading and trailing edges of blade

To improve the Surface Quality (SQ) of blade Leading and Trailing Edges (LTE), the polishing process of LTE with Abrasive Belt Flap Wheel (ABFW) was researched. According to the analysis of present problems existed in LTE polishing process, the ABFW flexible polishing process method was proposed based on ABFW machining characteristics. The primary process parameters affected SQ such as ABFW size, normal force, spindle speed and feed rate were determined on the basis of Material Removal Rate (MRR) with Preston equation. The polishing experiments were designed with response surface method, and the coupling effect between parameters on Surface Roughness (SR) were analyzed to establish the second order prediction model. The optimal parametric field and the optimum polishing parameters were obtained accordingly. The final LTE polishing experimental results showed that SQ was improved significantly with SR of less than 0.4μm, which met the quality requirement well.