From single-point to range optimization: A novel approach for determining robust polishing parameters of TC17 alloy blades

[摘要] To enhance the efficiency and robustness of flexible polishing for aeroengine blades, this study proposes a coupling-effect-based optimization algorithm to determine optimal process parameter ranges. Using Central Composite Design (CCD), quadratic response surface models were developed to correlate surface roughness (Ra) and residual stress with spindle speed (n), compression depth (ap), feed speed (vw), and abrasive mesh number (M). ANOVA confirmed the models’ statistical significance and superior goodness-of-fit. A Multi-Objective Genetic Algorithm (MOGA) was then employed to derive the Pareto optimal set, identifying parameters that satisfy engineering requirements (Ra < 0.4 μm) while minimizing residual stress. Based on response surface-based tolerance analysis, the optimal operational windows were established: spindle speed n ∈ [6773.6, 8000] r/min, compression depth ap ∈ [1.016, 1.6] mm, feed speed vw ∈ [100, 268.6356] mm/min, and abrasive mesh number M ∈ [496.4032, 800] #. Unlike conventional single-point estimates, this approach provides practical operational windows that significantly improve production efficiency and process robustness for flexible polishing applications.

[发布日期] 2026-07-01

[关键词] surface roughness;residual stress;optimization algorithm;response surface-based tolerance analysis;optimal operational windows