Abstract
Industrial robot-assisted abrasive cloth wheel (ACW) accurately polish blades is considered to be a challenging task, and it is necessary to realize the digitalization of the process. Due to the flexible contact properties of the abrasive cloth wheel and the curvature change of the blade surface, the microscopic material removal is not uniform and the blade surface roughness value is large. In this paper, a finite element simulation model of the contact between the abrasive cloth wheel and the blade is established, and analyze the contact profile and pressure distribution pattern in the contact area. Then use NURBS curve to extract the blade polishing area curve, and considering the flexible contact deformation between the abrasive cloth wheel and the blade surface when planning the step length and row spacing. The flexible adaptive trajectory planning method is simulated by offline programming software. Finally, experiments were carried out on a four-station wheel changing polishing platform. Simulation and experiments results show that the proposed flexible adaptive trajectory planning method can make the surface roughness of the convex and the concave $$R_{a} \le 0.3\;{\mu m}$$ , the surface roughness of the leading and trailing edges $$R_{a} \le 0.2\;{\mu m}$$ , and the total polishing efficiency increased by about 9.4%.
Highlights
The blade is the core component of the engine, and its polishing quality directly affects the service life and work efficiency of the engine
The multiaxis CUC machining technology improves the defects caused by manual polishing, its high cost, low flexibility, and limited working space restrict the diversified development of blade polishing
Wang et al [3] proposed an abrasive belt polishing path planning method for precise material removal based on Hertz contact theory
Summary
The blade is the core component of the engine, and its polishing quality directly affects the service life and work efficiency of the engine. The above integral blisk with the ACW polishing can better adapt to the geometric profile of leading and trailing edges, and obtain better polishing surface quality, but its application is a five-axis CUC machine tool, and the flexibility of the machine tool movement space is small, the size and variety of processing blades are small. The trajectory planning of the robot polishing free-form surface mentioned above is analyzed from the perspective of graphics and geometry, and it lacks consideration of the impact of dynamic contact force and material removal in the polishing process. This paper takes into account the influence of elastic deformation, conducts CAE modeling of the contact process of blades and the ACW, analyzes the contact profile and pressure distribution of the contact area, and proposes a flexible adaptive trajectory planning based on contact theory and material removal profile.
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