Machining behavior and experimental investigation of ultrasonic vibration assisted belt flapwheel flexible polishing

The integral blisk has been widely used in aerospace, and its structural performance is inextricably linked to the blade surface quality. To improve the surface integrity of polished surface, ultrasonic vibration assisted belt flapwheel flexible polishing (UBFP) is proposed. In this study, the polishing principle of UBFP and the effects of vibration on surface generation are investigated, and kinematic analyses and trajectory simulations are performed. Furthermore, the influences of the main processing parameters on the polishing force and surface roughness in UBFP are explored experimentally, and the sensitivity of the main parameters is distinguished by multi-parameter relative sensitivity analysis based on Monte Carlo simulation. The results show that the ultrasonic vibration contributes to the polishing process primarily through kinematic state changing and trajectories interlacing of abrasives. Compared with conventional belt flapwheel flexible polishing, the polishing force decreases by 15.72% and the surface roughness decreases by 17.39%. The compression depth is the most sensitive parameter in the process of UBFP. This study demonstrates the feasibility of UBFP and provides a theoretical and experimental reference for improving the polishing surface quality of the blisk blade.