Abstract
Fuel nozzle is a key part of aero-engines. Due to the particularity of fuel nozzle’s working environment, the high machining requirements for the surface quality and geometric accuracy of nozzle hole were put forward. The existing process is difficult to meet the machining requirements, so a new process is proposed, which is called the flexible single-pass honing. For the novel single-pass honing tool with diameter less than 1 mm, the laws are not very clear, so studies were carried out. Firstly, a novel cutting force model of single-pass honing was established, which explains the relationship between force and machining parameters. Based on the cutting force model, the influence laws of honing parameters on surface roughness, bore diameter, and shape accuracy were explored detailedly. Finally, according to the machining requirements of fuel nozzles, the honing process optimization was carried out, and the optimal parameters were obtained. Furthermore, precision control of surface quality and geometric accuracy for fuel nozzle single-pass honing was realized.
Highlights
Fuel nozzle is a key unit of aero-engines, which directly affects aero-engine performance [1]
The results showed that the spindle speed and feed speed were the decisive factors of roundness, while the surface roughness mainly depended on the particle size
The process characteristics are explored, which are cutting force, surface quality and geometric accuracy, and the process parameters are optimized according to the design requirements
Summary
Fuel nozzle is a key unit of aero-engines, which directly affects aero-engine performance [1]. The atomization of fuel nozzle is affected by the surface roughness and geometric accuracy of hole [2,3]. Arunachalam designed the orthogonal test, and systematically studied the influence of honing process parameters, including spindle speed, feed speed, removal allowance, abrasive particle size, workpiece material, fixture and tool length, on the cylindricity and surface roughness of single-pass honed hole [9]. The surface quality and geometric accuracy of single-pass honing are made a profound study, combining the axial force and torque of honing process parameters. Taking the surface quality and geometric accuracy as the optimization objects, the appropriate honing parameters are determined to realize the highefficiency and precision machining of fuel nozzle
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