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| Development of High Performance Grinding Processes to Challenge Physical Limitations: Application Prospects in Aeronautical Manufacture Engineering |
| JIN Tan 1 ，HE Xun 2 ，WANG Qirong 2 ，SHANG Zhentao 1 |
1. National Engineering Research Center for High Efficiency Grinding, Hunan University, Changsha 410082, China;
2. AECC South Industry Co., Ltd., Zhuzhou 412002, China |
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Abstract Grinding is widely applied in the aeronautical manufacture industry as an important process technique to guarantee the machining quality of those precision and ultra-precision components. Grinding has been developed into an enabling technology featuring high precision, high machining quality and also high process efficiency. It is capable to achieve high process efficiency with satisfactory machining accuracy and surface integrity. Driven by the application requirements and also the improvements of theoretical understanding, various high-performance grinding techniques have been developed beyond the limits of conventional grinding concepts. By using very high grinding wheel speeds, large depths of cut and also high worktable speeds, HEDG (High efficiency deep grinding) process can achieve extremely high machining efficiency, with good surface integrity on the ground workpiece surface. HEDG process has been successfully applied for the high efficiency grinding of turbine blade roots, showing excellent machining performance. HSSG (High speed stroke grinding) process is based on the linear drive technology for the worktable movement, pushing the feed rate toward an extremely high level, resulting in beneficial heat transfer conditions with most of the heat generated in the grinding zone being removed by the grinding chips, thus capable to achieve high grinding efficiency with good surface integrity. For the precision grinding of thin-walled slender shafts with high ratios of length over diameter, quick-point grinding technique provides the possibility to ensure both machining accuracy and machining efficiency. For the deepcut profile grinding of turbine blade roots using CFG (Creep-feed grinding) process, the heat transfer condition is rather complicated, further research work related with the heat transfer problems under the conditions of deep-cut and complex contact geometry is needed; Further research aspects also include process design method regarding the set up of parameters at different stages including roughing, semi-finishing and finishing, and intelligent process monitoring and optimization approaches. High efficiency deep grinding approach can also be applied for the deep-cut grinding of aluminum alloys widely used in aeronautical industry, whilst high speed and ultra-high speed grinding technique has good potentials to be applied for the machining of silicon carbide reinforced aluminum composites. High speed fly-grinding of the rotating blade tips assembled on the turbine disks, presents another application area of high speed and ultra-high speed grinding technique.
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2022, 
