镍基功能梯度渐变合金零件的磨削机理与工艺优化研究

镍基功能梯度渐变合金（NiFGS）是一种由多组分合金及强化相通过连续渐变复合而成的先进金属基复合材料。针对新一代高性能航空发动机NiFGS核心热端零件（涡轮叶片、燃烧室等）的增减材复合制造需求，为解决现阶段NiFGS零件的磨削去除机理不清、激光熔覆沉积/磨削复合加工后的梯度过渡相存在表面裂纹缺陷等问题，本项目立足于NiFGS零件组成材料的空间梯度渐变特性，旨在提高NiFGS零件的磨削质量及效率，通过研究NiFGS零件磨削的材料去除机理与工艺参数优化方法，探究材料渐变引发的梯度磨削力作用下的表面变形规律，探寻材料梯度、磨粒切入方向和磨削用量等工艺参数对磨削表面质量的影响机理，建立梯度过渡相磨削加工质量的评价和预测方法，通过智能群体/网络算法优化磨削工艺参数，获得合理的磨削用量抑制表面缺陷的产生，实现航空发动机NiFGS零件的增减材一体化快速制造，提升复杂梯度渐变合金的磨削技术应用水平。

Ni-based functional graded superalloy (NiFGS) is an advanced metal matrix composite with the gradient or continuous change of multicomponent alloys and strengthening phase. Hybrid additive and subtractive manufacturing of the NiFGS heat-resistant parts such as turbine blade and combustor becomes a key requirement of the next generation of aero engines. Currently, the grinding mechanism of NiFGS parts is still unclear, and the grinding defects such as cracks inevitably occur in the transitional phase after hybrid laser melting deposition and grinding processes. In order to address these issues as well as improve grinding quality and efficiency, starting from the graded properties of NiFGS materials in space, this project will study the material removal mechanisms and processing parameter optimization in grinding NiFGS parts. The surface deformation law affected by the dynamic grinding force caused by material gradient is explored. Influence mechanism of material gradient, abrasive cutting direction and grinding parameters on surface quality is studied to establish the evaluation and prediction methods of grinding quality for gradient phase. The swarm intelligence and network optimization algorithm is adopted to obtain proper parameters and restrain surface defects. This project will contribute to the additive and subtractive integrated rapid manufacturing of the NiFGS parts for aero engines and improve the grinding application level of complex functional graded superalloy.