Study on avoiding the knife marks of the blade after polishing by flap disc

The flap disc can realize shape-follow contact with the blade during the polishing process. However, the knife marks produced in the polishing process affect the surface integrity of polished blade seriously. Therefore, the phenomenon of knife marks in the polishing process is studied and analyzed. Firstly, the first reason analysis of the knife marks has been made according to the distribution characteristics of the knife marks on the blade surface and the abrasive wear on the surface of flap disc. The force deformation of blade is analyzed theoretically and simulated. Based on the results of theoretical and simulation, the polishing path of flap disc is modified and verified by experiment. And then, the second reason analysis of the knife marks has been made according to the distribution characteristics of knife marks on blade surface and the abrasive wear on the surface of flap disc after tool trajectory optimization. According to the results of the second reason analysis, taking a single row of abrasives, the force of abrasives in polishing process is calculated theoretically. Shape optimization of flap disc has been made according to the force-deformation curve of single row abrasives. The polishing surface qualities of blades before and after optimization were compared. The experimental results show that the knife marks of polished blade surface are improved obviously after optimizing the tool trajectory. The knife marks on the polished blade surface are basically eliminated after optimizing the shape of flap disc. The surface roughness and consistency improved further.