Scale dependence analysis of two-dimensional vibrational polishing of shaped holes for aerospace heat dissipation

The dimensions of specialized cooling holes in aerospace turbine blades significantly impact their thermal dissipation capabilities. Two-dimensional vibration-assisted processing, an employed technique for shaping these holes, produces non-circular polishing regions as the tool follows closed Lissajous patterns. This innovation presents a novel approach for refining surfaces, particularly for high numerical aperture cooling holes. However, prior research has predominantly concentrated on optimizing two-dimensional vibration control and process parameters or assessing its applicability to challenging materials, with limited analysis on the processing scales of shaped holes. This study delves into the scale-dependent characteristics of two-dimensional vibration-assisted processing by varying the amplitude-to-contact radius ratio. Research suggests that higher ratios yield a square polishing trajectory, while lower ratios gradually transform the polishing region into a circular shape. Additionally, this study analyzes the varying removal mechanisms and associated processing scale considerations under different ratios. The above analysis enhances our understanding of the interplay between processing parameters and scales in shaped hole processing, providing valuable insights for precision optimization in this field.