Surface roughness prediction and parameters optimization in grinding and polishing process for IBR of aero-engine

In order to improve surface quality and reduce surface roughness of integrally bladed rotors (IBRs), the optimizations of grinding and polishing process parameters, such as abrasive size, contact force, belt linear velocity, and feed rate, are carried out in this study. Firstly, the optimal range of each factor is obtained by single-factor experiment, and a surface roughness prediction model is generated according to the central composite design experiments and quadratic regression design technology. Secondly, the optimal level of each factor is confirmed through the surface roughness prediction model, and the response surface of the optimal level of each factor is drawn using Matlab. Then, the optimum process parameters are determined by analyzing the response surface. Finally, the optimum process parameters are selected in the grinding and polishing experiments for IBR. The experimental results show that grinding and polishing with the optimum parameters obtained in this study enhances the machining quality significantly. The surface roughness of IBR improved greatly (nearly 25%) compared with grinding using normal parameters.