Study on material removal of double abrasive grains in ultrasonic assisted abrasive cloth wheel of GH4169 alloy blade

As a critical component of aero-engines, the processing quality of the blade has a significant impact on the engine’s overall performance and service life. First, from the perspective of double abrasive grains, two finite element models—simultaneous and sequential scratches—are established. The interaction between the two abrasive grains affects not only the polishing force and chip formation but also the surface morphology of the processed workpiece. Second, the effects of abrasive grain rake angle, grain spacing, and ultrasonic amplitude on polishing force, chip formation, and surface morphology are analyzed using a single-factor method. Finally, conventional polishing and ultrasonic vibration-assisted polishing experiments using an abrasive cloth wheel are conducted. The results show that varying the transverse spacing between the abrasive grains reduces the polishing force on the second abrasive grain and leads to the formation of broken chips. Compared to conventional polishing, ultrasonic vibration-assisted polishing reduces the polishing forces by 9% and 8% in the tangential and normal directions, respectively, while also improving surface morphology and producing crushed chips.