复材叶片前缘加强边加工残余应力变形控制方法

doi:10.7527/S1000-6893.2025.32693

Abstract

Abstract:

The titanium alloy leading edge protection cap is a critical component of large composite blades， characterized by a complex thin-walled V-shaped long slot structure with deep， narrow， and low-stiffness features. Both its inner cavity and outer profile require shaping through multi-axis precision machining. However， the unbalanced distribution of residual stress introduced by the machining process between the inner cavity and outer profile can induce significant bending-torsion coupling deformation， leading to out-of-tolerance deviations in key dimensions such as the contour accuracy. Therefore， a residual stress deformation control method for the protection cap is proposed based on the optimization of the cutter axis vector in machining outer profile. By optimizing the cutter axis vector in multi-axis machining， this method actively regulates the residual stress distribution on the outer profile， balancing it with that in the inner cavity to achieve precise control of the bending-torsion deformation. Firstly， the hyperbolic tangent function is employed to characterize the residual stress gradient distribution induced by multi-axis machining of TC4 titanium alloy. Subsequently， a finite element simulation model for the residual stress-induced deformation of the protection cap is established on the Abaqus software platform， where the residual stress is applied as loads using the thin-shell stress-fitting method. Based on this model， a quantitative mapping relationship between the cutter tilt angle and the deformation at key locations is established， thereby completing the optimization of the cutter axis vector for outer profile machining. Finally， the effectiveness of the proposed method is validated through machining experiments on multiple parts. Experimental results show that the contour error of the optimized parts is reduced by an average of 23.41%. This method provides a reliable technical solution for the high-precision multi-axis machining of titanium alloy leading edge protection caps， holding direct engineering significance for enhancing the manufacturing quality and service reliability of composite blades.

Key words: leading edge protection cap, TC4 titanium alloy, multi-axis machining, residual stress, cutter axis vector, deformation control

CLC Number:

V261.2⁺3

Qi QI, Jinhua ZHOU, Junxue REN, Zongyuan WANG. Residual stress deformation control method of composite blade leading edge protection cap machining[J]. Acta Aeronautica et Astronautica Sinica, 2026, 47(8): 432693.

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编号	1	2	3	4	5	6	7	8
σ_x /MPa	-172.39	-136.04	-129.54	-125.46	-126.72	-133.81	-142.48	-152.68
σ_y /MPa	-124.86	-112.25	-105.48	-102.34	-106.79	-109.46	-114.14	-119.86

实验编号	1	2	3	4	5	6	7	8	9	10	11	12	13	14	15	16
θ/（°）	45	45	55	55	60	60	65	65	70	70	75	75	80	80	85	85
走刀路径	竖	横	竖	横	竖	横	竖	横	竖	横	竖	横	竖	横	竖	横
最大挠度/mm	0.126	0.079	0.091	0.071	0.084	0.065	0.080	0.063	0.081	0.067	0.087	0.068	0.095	0.071	0.104	0.075

实验编号	σ_x		σ_y
实验编号	k_x	ω_x	k_y	ω_y
1	1.724	2.688	1.249	2.432
2	1.360	2.821	1.123	2.622
3	1.295	2.917	1.055	2.681
4	1.255	2.956	1.023	2.704
5	1.267	2.923	1.068	2.683
6	1.328	2.902	1.095	2.672
7	1.425	2.857	1.141	2.631
8	1.527	2.813	1.199	2.585

编号	刀具型号	θ/（°）	切削速度/ （m∙min^-1）	每齿进给量/（mm∙z^-1）	切削深度/mm
1	BR2.5C3.0	65	110	0.043	0.2
2	BR2.0C2.8	70	88	0.032	0.2
3	BR1.5C2.7	75	61	0.031	0.2
4	BR1.2C2.0	80	42	0.027	0.2

编号	σ_x			σ_y
编号	k_x	ω_x	R²	k_y	ω_y	R²
1	1.84	6.38	0.985 2	1.35	4.58	0.952 6
2	2.11	4.26	0.963 2	2.28	3.88	0.947 3
3	1.96	5.14	0.974 4	2.97	7.21	0.956 8
4	4.33	4.07	0.993 1	4.83	6.25	0.935 7

Residual stress deformation control method of composite blade leading edge protection cap machining

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加强边位置	θ/（°）
加强边位置	区域1	区域2	区域3	区域4
叶盆	65	70	75	80
叶背	65	70	75	80

编号	内腔和外型	加强边位置	区域	等效残余应力
编号	内腔和外型	加强边位置	区域	σ_avg-_x /MPa	σ_avg-_y /MPa
1	内腔	叶盆	1	-89.13	-80.27
2	内腔	叶盆	2	-81.80	-95.38
3	内腔	叶盆	3	-82.41	-93.37
4	内腔	叶盆	4	-174.30	-132.62
5	内腔	叶背	1	-89.13	-80.27
6	内腔	叶背	2	-81.80	-95.38
7	内腔	叶背	3	-82.41	-93.37
8	内腔	叶背	4	-174.30	-132.62
9	外型	叶盆	-	-36.32	-32.18
10	外型	叶背	-	-36.32	-32.18

编号	θ/（°）	变形量/mm
编号	θ/（°）	监测点1	监测点2	监测点3	监测点4	监测点5	监测点6
1	45	-0.310	-0.275	-0.025	0.198	-0.265	-0.061
2	55	-0.422	-0.213	-0.017	0.236	-0.211	-0.032
3	65	-0.444	-0.205	-0.015	0.243	-0.195	-0.029
4	75	-0.430	-0.211	-0.016	0.239	-0.205	-0.031
5	85	-0.344	-0.258	-0.021	0.210	-0.239	-0.056

区域	f/（mm∙min^-1）	n/（r∙min^-1）	a_p/mm	a_e/mm	θ/（°）
1	1 400	7 000	0.14	0.32	86.97
2	1 400	7 000	0.14	0.32	80.26
3	1 400	7 000	0.14	0.32	73.55
4	1 400	7 000	0.14	0.32	66.84
5	1 400	7 000	0.14	0.32	60.13

零件编号	位置度误差/mm		扭转角误差/（΄）		轮廓度误差/mm
零件编号	优化前	优化后	优化前	优化后	优化前	优化后
1	0.198	0.156	14.25	10.61	0.463	0.349
2	0.203	0.163	15.36	11.21	0.472	0.364
3	0.179	0.142	13.89	9.58	0.467	0.355
4	0.216	0.175	15.81	12.03	0.479	0.374

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