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Vibratory finishing for the cavity of aero-engine integral casting casing: mechanism analysis and performance evaluation

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Abstract

Severe casting defects exist on the cavity surface of aero-engine integral casting casing, leading to substandard cleanliness and surface integrity, which restricts the service performance of the casing. The finishing process for the complex cavity of casting casing is one of the technical bottlenecks in aero-engine manufacturing. Vibratory finishing has excellent potential for closed cavities because of the process media’s fluidized nature. In this work, taking the particle separator main casing of turboshaft aero-engine as a practice, based on the principle of vibratory finishing, a new idea of pre-loading the media and changing the spatial posture of the casing was proposed, and processing experiments were carried out. The vibration acceleration of the casing and the dynamic stress generated on the surface were measured, and the unfinished and finished surfaces were analyzed. The dynamic stress on the casing surface is far less than the fatigue strength of aluminum alloy (AlSi7Mg), which proves the feasibility of vibratory finishing for the casting casing. Meanwhile, the collision and scratching of the steel shot caused the surface roughness of the cavity to drop by 2 ~ 4 grades, and most of the carbon elements were removed. The finished surfaces had better surface morphology and cleanliness. Denser oxide film and lower surface roughness significantly improved the service performance of the casing, in which the corrosion resistance and mechanical properties were improved considerably. This process can provide a new approach for cavity finishing of other types of casings.

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Funding

The work was co-supported by the National Natural Science Foundation of China (Grant Nos. 52075362, 51875389, and 51975399) and the Scientific and Technological Innovation Project for Excellent Talents in Shanxi Province (Grant No. 201805D211031).

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, China

    Yupeng Hao, Shengqiang Yang & **uhong Li

  2. Shanxi Province Key Laboratory of Precise Machining, Taiyuan, 030024, China

    Yupeng Hao, Shengqiang Yang, Wenhui Li & **uhong Li

  3. Langfang North Tianyu Mechanical Electronical Technology Co., Ltd, Langfang, 065000, China

    Dongxiang Li

  4. College of Aeronautics and Astronautics, Taiyuan University of Technology, Taiyuan, 030024, China

    Wenhui Li

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  1. Yupeng Hao
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Yupeng Hao designed and performed the manuscript, analyzed the data, and drafted the manuscript. Shengqiang Yang conceived and supervised the study, and edited the manuscript. Dongxiang Li performed the experiments, and Wenhui Li and **uhong Li analyzed the data. All authors read and approved the manuscript.

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Correspondence to Shengqiang Yang.

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Hao, Y., Yang, S., Li, D. et al. Vibratory finishing for the cavity of aero-engine integral casting casing: mechanism analysis and performance evaluation. Int J Adv Manuf Technol 125, 713–729 (2023). https://doi.org/10.1007/s00170-022-10728-9

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