A prediction model of residual stress for belt‐grinding blade based on geometrical characteristic and progressive wear of abrasive grains

Abstract The formation mechanism of residual stress on the machined surface of belt grinding is sophisticated, and residual stress is an important factor affecting the fatigue life of aero‐engine blades. In this study, a prediction model of residual stress in a belt grinding blade is proposed with the geometrical characteristics and progressive wear of the grains as the research topic. By extracting the morphological features of abrasive belt, the residual stress based on different geometrical characteristics of grains (pyramidal, hexahedral, spherical, and conical belts) were investigated, and the optimal grain geometry was determined to be a uniformly arranged positive quadrilateral cone. Accordingly, a grinding experiment with a pyramidal belt was conducted to obtain an experienced model of the grain wear height. A numerical simulation model of the grain wear evolution under four wear states (no abrasion, early abrasion, middle abrasion, and late abrasion) was developed. Additionally, more detailed progressive wear of the abrasive grains was also applied to grind the entire profile of the complex curved blade. The residual stress on the blade surface was mainly compressive, and the surface stress values were distributed between −385 and −117 MPa with the service life of the pyramidal abrasive belt.