Design model for the knowledge-based adjustment of the edge zone and surface properties of additive-manufactured components for guided centrifugal finishing

民用航空面临的挑战是在科普不断增加的乘客量的同时减少污染物排放。因此，对能够提高发动机效率的创新制造技术的需求很高。增材制造可以通过优化具有复杂几何形状的部件（例如涡轮机叶片）的拓扑结构来实现重量减轻。因此，涡轮机叶片的增材生产可以节省燃料并提高发动机效率。由于增材制造导致的高表面粗糙度和热影响的边缘区性质，边缘区的后处理通常是必要的。导向离心光整加工提供了均匀加工具有复杂几何形状的部件表面的可能性。在导向离心光整加工中，工艺输入变量与产生的边缘区域和表面特性之间的因果关系尚未得到系统的研究。因此，基于知识的工艺设计是不可能的。因此，该研究项目的目标是建立一个启发式解释模型，解释在引导离心抛光过程中，增材制造部件的边缘区域和表面特性对局部接触条件的影响。过程输入变量和局部接触条件之间的因果关系被识别。在此基础上，将开发一个数值模型，代表磨料介质和工件之间的接触。数值模型能够预测作为局部接触条件的函数的所得边缘区域特性。随后，局部接触条件和边缘区域之间的因果关系和由Inconel 718制成的增材制造部件的表面特性在引导离心抛光后被识别。结果结合在一个解释性模型，解释的过程输入变量和边缘区域和表面性能的引导离心抛光之间的因果关系。

The challenge facing civil aviation is to cope with increasing passenger volumes while simultaneously reducing pollutant emissions. Therefore, there is a high demand for innovative manufacturing technologies that make it possible to increase engine efficiency. Additive manufacturing makes it possible to achieve weight savings by optimizing the topology of components with complex geometries such as turbine blades. The additive production of turbine blades can thus save fuel and increase engine efficiency. Due to the high surface roughness and thermally influenced edge zone properties resulting from additive manufacturing, post-processing of the edge zone is often necessary. Guided centrifugal finishing offers the potential to evenly machine the surface of components with a complex geometry. The cause-effect relationships between the process input variables and the resulting edge zone and surface properties in guided centrifugal finishing have not yet been systematically investigated. A knowledge-based process design is therefore not yet possible.The goal of the research project is therefore a heuristic explanatory model which explains the influence of the edge zone and surface properties of additively manufactured components during guided centrifugal finishing as a function of the local contact conditions. The cause-effect relationships between the process input variables and the local contact conditions are identified. On the basis of the findings, a numerical model will be developed which represents the contact between the abrasive media and the workpiece. The numerical model enables the prediction of the resulting edge zone properties as a function of the local contact conditions. Subsequently, the cause-effect relationships between the local contact conditions and the edge zone and surface properties of additively manufactured components made of Inconel 718 are identified after guided centrifugal finishing. The results are combined in an explanatory model which explains the cause-effect relationships between the process input variables and the edge zone and surface properties for the guided centrifugal finishing.