Prediction of contact characteristics of abrasive belt compliant grinding for aircraft blades

Due to the characteristics of thin-walled curved surface, wall thickness variations, and cantilevered machining fixtures, the mechanical state of the different contact positions of aircraft engine blades varies significantly during the grinding process. The different contact interactions between the contact wheel and the blade lead to changes in material removal efficiency and surface quality. To achieve contact state control during the blade grinding process, a novel flexible abrasive belt grinding device was designed and developed, taking into account the compliance of the rubber wheel. The significant effect of compliance parameters on the grinding contact state was verified through simulation. The grinding contact pressure distribution and normal contact force at different positions in the blade width and length directions were studied, and a prediction model for the maximum contact pressure and normal contact force was established based on back propagation neural networks. The results showed that with the increase in contact wheel compliance, the effective contact range increased; the pressure distribution gradually became uniform, and showed a double-elliptical distribution. The maximum contact pressure was significantly reduced, with a reduction of up to 46.00%. As the grinding contact position moved towards the weak rigidity area of the blade, the contact pressure distribution became more uniform. The normal contact force was significantly reduced, with a maximum reduction of 68.49%. The mean average percentage error (MAPE) of the prediction model was small, verifying the effectiveness of the model. The research results of this manuscript laid a foundation for achieving consistent control of the blade grinding material removal rate through contact wheel compliance adjustment.