K444材料是我国自主研发的耐腐蚀性镍基高温合金，具有优异的高温力学性能和耐热腐蚀性能，主要用于制造舰载和陆用燃气轮机的涡轮叶片。由于该材料含有较多亲氧元素和高强韧特性，加工难度大，导致加工效率低下、砂轮磨损严重并极易发生磨削烧伤，加工表面完整性难以保证。目前普通刚玉砂轮磨削K444材料面临砂轮过度修整、难以实现工艺进一步优化等问题，影响这种高温合金涡轮叶片的推广应用。因此，开展K444镍基高温合金高效成形磨削、表面完整性形成规律与控制研究对提高燃气轮机涡轮叶片服役性能具有重要意义。

  论文旨在研究砂轮修整工艺与修整后磨削状态间的关系、K444材料的磨削特性及对加工表面耐腐蚀性能影响规律、磨削过程中温度与残余应力分布、砂轮磨损等，优选出适合K444镍基高温合金榫齿成形磨削工艺，实现燃气轮机涡轮叶片榫齿的高效高表面完整性加工。主要研究内容及成果如下：

  （1）开展新型刚玉砂轮与陶瓷CBN砂轮修整研究，通过修整力状态信号监测，引入声发射技术和修整轨迹长度概念，对修整过程中修整工具与砂轮接触的微观形貌特征进行研究。结果表明，声发射均方根电压可以反映金刚石磨粒的磨损行为并敏锐反馈出磨粒发生剧烈磨损的波动状态；探明了微晶刚玉磨粒发挥自锐特性的修整状态，为修整过程监测、工具磨损检测提供了参考。

  （2）采用刚玉砂轮（白刚玉砂轮与新型微晶刚玉砂轮）与超硬砂轮（电镀CBN砂轮与陶瓷CBN）工具，探明了不同磨削工艺条件对K444材料磨削加工性的影响。利用磨削力、磨削温度、磨削表面形貌、砂轮磨损量、砂轮磨损形貌等特征，综合评价了K444材料的磨削加工性，为后续工艺优化提供了依据。

  （3）利用电化学极化曲线和阻抗谱曲线对已加工表面的腐蚀性能开展研究，并对材料的腐蚀形貌及磨削表面的元素分布特征进行分析。结果表明，磨削表面缺陷和形貌直接影响磨削表面的腐蚀坑深度、相腐蚀的趋向性及元素分布状态。

  （4）开展K444榫齿成形磨削与表面完整性研究，建立成形磨削温度和残余应力分布预测模型，并与实测值对比分析，验证了模型的准确性，为实现燃气轮机涡轮叶片榫齿的高效高表面完整性加工提供了支撑。

The nickel-based superalloy K444 is a corrosion-resistant material independently developed in China. It can be applied to certain types of ship-based and land-based gas turbines as the blades, with the excellent high-temperature mechanical performance and hot-corrosion resistance. However, high strength and toughness properties, as well as the presence of a relatively high amounts of oxidized elements lead to the low machining efficiency, rapid tool wear and grinding burns. Improving processing efficiency is of crucial importance for the preparation of turbine blades. Improving and controlling processing surface integrity is essential for enhancing the performance of gas turbines in service. At present, the existing technology faces problems such as excessive dressing, low machining efficiency, unstable processing surface quality, burning, inability to further optimize the process with ordinary alumina grinding wheels. The incomplete understanding of the characteristics of the obtained grinding surfaces, unclear rules of temperature distribution and surface residual stress state of the ground surface, make it impossible to make accurate predictions. This has led to an increase the cost of machining K444 materials and limited its use.

This article aims to conduct research on realizing high-quality and high-efficiency forming and controlling surface integrity of nickel-based high-temperature alloys. To develop rules of grinding surface integrity by exploring the relationship between grinding wheel and the state of grinding after dressing. Predict the temperature and residual stress distribution, investigate the grinding wheel wear rules and other surface integrity. The main research content and achieved results are as follows:

(1) The dressing of a new type of microcrystalline alumina grinding wheel and ceramic CBN grinding wheel was carried out. By monitoring the dressing force signal, introducing acoustic emission technology and the concept of dressing trajectory length, the micro-morphological characteristics of the contact between the dressing tool and grinding wheel during were studied. Which revealed the characteristics of grinding wheel under different states, and clarified the relationship between self-sharpening properties and dressing status. This provided a reference for monitoring the dressing process and detecting tool wear.

(2) The grinding characteristics of K444 material were comprehensively analyzed. Using alumina grinding wheels (white alumina grinding wheels and new microcrystalline alumina grinding wheels) and super-hard grinding tools (electroplated CBN grinding wheels and ceramic CBN), its grinding force, temperature, surface morphology, wheel wear andmorphology were described under different grinding conditions. The grinding characteristics of K444 material were comprehensively evaluated, providing practical guidance for subsequent parameter optimization.

(3) The influence of different grinding surface states on corrosion behavior was elucidated, including ground surface micro-morphology, element distribution characteristics, etc. The corrosion resistance properties were studied by electrochemical polarization curves and impedance spectroscopy curves. The results showed that the surface defects and morphology directly affect the depth of corrosion pit, the trend of phase corrosion and the distribution of elements.

(4) A predictive model was established for the profile grinding process and surface integrity of K444 blade root. The grinding temperature and residual stress distribution characteristics were verified, which can be effectively predicted. The recommended optimized processing surface integrity was also verified, enabling high-quality and high-efficiency processing of K444 blade root.

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