CN116038505B - Fan rotor blade polishing method based on grading - Google Patents
Fan rotor blade polishing method based on grading Download PDFInfo
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- CN116038505B CN116038505B CN202310345229.8A CN202310345229A CN116038505B CN 116038505 B CN116038505 B CN 116038505B CN 202310345229 A CN202310345229 A CN 202310345229A CN 116038505 B CN116038505 B CN 116038505B
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- polishing
- fan rotor
- rotor blade
- removal
- grading
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B21/00—Machines or devices using grinding or polishing belts; Accessories therefor
- B24B21/16—Machines or devices using grinding or polishing belts; Accessories therefor for grinding other surfaces of particular shape
- B24B21/165—Machines or devices using grinding or polishing belts; Accessories therefor for grinding other surfaces of particular shape for vanes or blades of turbines, propellers, impellers, compressors and the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B21/00—Machines or devices using grinding or polishing belts; Accessories therefor
- B24B21/18—Accessories
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
- B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent
- B24B49/04—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent involving measurement of the workpiece at the place of grinding during grinding operation
- B24B49/045—Specially adapted gauging instruments
Abstract
The invention belongs to the technical field of repair of aeroengine blades, and particularly relates to a class-division-based fan rotor blade polishing method, which comprises the steps of detecting defect data on the surface of a fan rotor blade by using surface defect recognition equipment, inquiring an acquired process parameter library, determining removal quantity classes corresponding to the acquired defect data, inputting the determined removal quantity classes into a management and control software system, matching with polishing parameters of the corresponding removal quantity classes, and polishing the fan rotor blade in polishing equipment.
Description
Technical Field
The invention belongs to the technical field of repair of aero-engine blades, and particularly relates to a method for precisely polishing the surface of a fan rotor blade severely damaged by foreign objects.
Background
The dimensional accuracy and surface quality of a fan rotor blade as one of the core components of an aircraft turbine engine directly affect the starting performance and fatigue life of the aircraft engine.
When repairing the fan rotor blade of the aeroengine, the surface damage defect is required to be removed through polishing, the polishing removal amount is different because of different damage degrees of each blade or each batch of blades, the polishing removal amount is generally about 0.02-mm-0.1 mm, the traditional mode is performed in a manual polishing mode while checking, the over-polishing and under-polishing conditions exist, the blade rejection rate is improved due to over-polishing, and the production period is delayed due to under-polishing.
In order to improve the accuracy of the polishing removal amount, domestic repair enterprises introduce an automatic polishing technology, for example, chinese patent application No. CN202010966800.4 discloses a blade milling and polishing integrated forming method, a clamp is used for clamping and fixing a fan blade and milling is carried out, after milling is finished, a measuring tool is used for measuring the fan blade, and the width of a region with out-of-tolerance size at the position of an air inlet side and an air outlet side is recorded; the measuring result and the fan blade structure polish and partition the fan blade; programming and selecting polishing parameters, setting polishing steps, and performing polishing track simulation by using motion simulation software;
however, in the prior art, the surface faults cannot be accurately removed according to fixed technological parameters due to different removal requirements of each piece or batch of blades, so that a method capable of accurately removing the surface faults of the blades according to the blade fault level is developed, and the method has important significance in improving the fault removal accuracy of the fan rotor blades of the aero-engine, improving the repair quality reliability and reducing the repair rejection rate of the blades.
Disclosure of Invention
In order to solve the technical problems, the invention adopts the following technical scheme:
a method of polishing a fan rotor blade based on grading, comprising the steps of:
s1: detecting defect data of the surface of the fan rotor blade using a surface defect identification device;
s2: inquiring the acquired process parameter library, and determining the removal level corresponding to the defect data acquired in the step S1;
s3: inputting the removal amount grade determined in the step S2 into a control software system, matching with each polishing parameter of the corresponding removal amount grade, and polishing the fan rotor blade in polishing equipment.
Further, the process parameter library acquisition comprises the following steps:
s2-1: dividing the removal amount into a plurality of groups of grades by taking the maximum defect depth detected by the surface recognition equipment as an interval range of 0.03 mm;
s2-2: after a certain group of removal rate grades are selected, measuring the wall thickness reduction of each section of the fan rotor blade before and after polishing by using a measuring instrument to evaluate the polishing removal rate;
s2-3: testing the polishing removal amount of each blade in the whole life cycle of a single abrasive belt;
s2-4: recording linear speed, feeding speed and polishing pressure parameters of the abrasive belt of the polishing equipment in the group of removal quantity grades;
s2-5: testing and recording the corresponding parameters of the residual removal level according to the steps;
s2-6: and selecting a fan rotor blade to carry out production verification of the removal quantity, and verifying whether the service life of the abrasive belt and the removal quantity of the fan rotor blade meet the requirements of a process parameter library.
Further, in S2-2, the wall thickness and the maximum wall thickness of the front and rear edges of each section of the fan rotor blade at a fixed distance are also evaluated.
Further, in S2-2, the wall thickness of at least three sections above, in and below the fan rotor blade is measured, each section having a wall thickness at a fixed distance from the leading edge, a wall thickness at a fixed distance from the trailing edge, and a maximum wall thickness.
Further, the polishing is stopped by monitoring the thickness of the abrasive belt after each fan rotor blade is polished until the thickness of the abrasive belt is reduced to a thickness that does not have the ability to remove material.
Further, the constant polishing removal rate is targeted, and parameters of the polishing process in the whole life cycle of the abrasive belt are corrected.
Further, in the process parameter library, the removal level is classified into three groups of levels.
Further, three sets of removal amount classification ranges are respectively: 0.01 mm-0.03 mm, 0.04 mm-0.06 mm, 0.07 mm-0.09 mm.
Further, the defect data includes depth and width data of the scratch.
Further, the measuring instrument is a three-coordinate measuring instrument.
Compared with the prior art, the invention has the following beneficial effects:
(1) The removal amount of the surface fault polishing and removing of the fan rotor blade is subdivided, the polishing removal amount is precisely controlled by equipment, the precision level and controllability of polishing and removing materials are improved, and over-polishing and under-polishing of the blade are prevented.
(2) The method for establishing the process database in the whole life cycle of the abrasive belt consumable realizes the purpose of automatically polishing the fan rotor blades in the same batch according to a certain removal level.
(3) The method can be used for online operation by adopting flexible self-adaptive polishing equipment and a fault level-based process database management system, solves the process problem that the removal amount is unstable due to abrasion of the abrasive belt in the whole life cycle of the abrasive belt, solves the problem that the surface fault cannot be accurately removed in the automatic polishing repair process of the fan rotor blade of the current aeroengine, effectively controls the subdivision level of the removal amount, and improves the removal amount control precision in the automatic assembly line polishing of the fan rotor blade in whole batches and in large batches.
Drawings
FIG. 1 is a schematic illustration of a precise control model for removal of an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
FIG. 2 is a schematic illustration of a polishing process for an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
FIG. 3 is a schematic representation of a polished wall thickness position of a fan rotor blade in an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
FIG. 4 is a graph showing the change of the linear velocity parameters of the polishing process before and after adjustment in an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
FIG. 5 is a graph showing the variation of polishing pressure parameters of a polishing process before and after adjustment in an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
FIG. 6 is a graph showing the variation of the polishing process feed rate parameters before and after adjustment in an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
FIG. 7 is a graph showing the variation of the polishing process removal parameters before and after adjustment in an embodiment of a method for polishing fan rotor blades based on classification in accordance with the present invention;
Detailed Description
In order that those skilled in the art will better understand the present invention, the following technical scheme of the present invention will be further described with reference to the accompanying drawings and examples.
Wherein the drawings are for illustrative purposes only and are shown in schematic, non-physical, and not intended to be limiting of the present patent; for the purpose of better illustrating embodiments of the invention, certain elements of the drawings may be omitted, enlarged or reduced and do not represent the size of the actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted, and that like or similar reference numerals in the drawings correspond to like or similar components in the embodiments of the present invention; in the description of the present invention, it should be understood that, if the terms "upper", "lower", "left", "right", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, only for convenience in describing the present invention and simplifying the description, rather than indicating or implying that the apparatus or elements being referred to must have a specific orientation, be constructed and operated in a specific orientation, so that the terms describing the positional relationships in the drawings are merely for exemplary illustration and should not be construed as limiting the present patent, and that the specific meaning of the terms described above may be understood by those of ordinary skill in the art according to specific circumstances.
Examples:
the flexible self-adaptive polishing technology adopts a numerical control abrasive belt grinding technology with pressure control, and the linear speed, the feeding rate and the polishing pressure during abrasive belt grinding are controlled by a production control system. And obtaining a process database in the whole life cycle of the abrasive belt by accurately acquiring the relation between the removal amount and the process parameters through experiments, and achieving the aim of accurately controlling the polishing removal amount according to different grades, wherein the process database is a schematic diagram of an accurate removal amount control model of the invention as shown in figure 1.
The following description is made by way of example of an automatic polishing precision control method for titanium alloy fan rotor blades of an aeroengine:
the surface defect recognition equipment is used for detecting surface damage and scratch depth and width data of the fan rotor blade to assist in determining polishing material removal quantity requirements of the fan rotor blade, for example, the surface defect recognition equipment is used for detecting the maximum defect depth of 0.09mm of a certain type of fan rotor blade, the removal quantity is classified into one class according to the repair requirements of the fan rotor blade, the control precision of the removal quantity of the automatic processing equipment is tested to be about +/-0.015 mm according to the range of 0.03mm, the removal quantity of 0.01-0.03 mm is classified into a first class, the removal quantity of 0.04-0.06 mm is classified into a second class, and the removal quantity of 0.07-0.09 mm is classified into a third class.
The thickness reduction of each section wall before and after polishing of the fan rotor blade is measured by using a three-coordinate measuring instrument to evaluate the polishing removal amount, and the wall thickness and the maximum wall thickness of the fixed distance between the front edge and the rear edge of each section of the blade are mainly evaluated.
And testing the removal amount of polishing of each blade in the whole life cycle of 1 abrasive belt according to a certain removal amount grade, wherein the automatic polishing equipment has a pressure control function, can realize random self-adaptive automatic polishing of complex curved blades, can adjust polishing pressure, and acquires the removal amount and a process parameter library through a large number of data tests and verification and correction of process parameters.
The specific implementation process of the relation between the removal level and the technological parameters can be obtained by establishing a blade high-precision force control conformal precise numerical control abrasive belt grinding program, polishing along the longitudinal direction of the blade, wherein the roughness reaches Ra0.4μm after polishing, and the polishing process and parameters are shown in figure 2.
Wall thickness position is schematically shown in fig. 3, wall thickness of at least three sections of the blade is measured by using three coordinates, wherein the wall thickness of each section comprises at least three points of wall thickness of a fixed distance from the front edge, wall thickness of a fixed distance from the rear edge, maximum wall thickness and the like, wherein Cq2 is the wall thickness at a position of 2mm from the front edge of the blade, cq4 is the wall thickness at a position of 4mm from the front edge of the blade, cmax is the maximum wall thickness of the blade, ch2 is the wall thickness at a position of 2mm from the rear edge of the blade, ch4 is the wall thickness at a position of 4mm from the rear edge of the blade, and Ch10 is the wall thickness at a position of 10mm from the rear edge of the blade.
And obtaining the empirical data of the removal amount and the polishing process parameters through a preliminary polishing test, selecting a removal amount grade, selecting a group of fixed abrasive belt linear speed, feeding rate and polishing pressure parameters according to the empirical data, continuously polishing the blade basin surface because the damage of the repaired blade is mainly concentrated on the blade basin surface, monitoring the thickness of the abrasive belt after each blade is polished until the thickness of the abrasive belt is thinned to the thickness when the abrasive belt does not have the material removing capability, and stopping polishing.
The thickness of each polished blade is measured in three coordinates, the polishing removal amount is calculated, and the thickness of the abrasive belt, the removal amount of the material and the polishing process parameter change chart can be obtained, as shown in fig. 4-7, it can be seen that the removal amount is reduced along with the abrasion of the abrasive belt, wherein the ordinate of fig. 4 is the linear velocity v (m/s), the abscissa is the polishing blade serial number, the ordinate of fig. 5 is the polishing pressure F (N), the abscissa is the polishing blade serial number, the ordinate of fig. 6 is the feeding velocity F (mm/min), the abscissa is the polishing blade serial number, the ordinate of fig. 7 is the removal amount (mm), and the abscissa is the polishing blade serial number;
the method aims at constant polishing removal quantity, corrects the technological parameters of each blade in the whole life cycle of the abrasive belt, has the following technological problems that grinding vibration lines are easy to occur when only pressure is adjusted, the abrasive belt life is reduced and the surface quality of the blade is influenced when only linear speed is adjusted, and the blade polishing efficiency is greatly reduced when only feeding rate is adjusted, so that the polishing pressure, the linear speed and the feeding rate are not adjusted independently when correction is carried out, and a large amount of total life removal quantity of the abrasive belt and quantitative verification of the technological parameters are carried out, so that the technological parameter diagram shown in figure 5 can be obtained, and it can be seen that the relative stability of the polishing removal quantity is maintained through the change of the technological parameters.
Repeating the steps to obtain the removal amount and polishing process parameter library under different removal amount grades;
the following table shows the process parameter library for the second grade removal (0.04 mm to 0.06 mm)
According to the three-grade process parameter library obtained by the method, the blades are selected for production verification of removal amount, whether the service life of the abrasive belt and the removal amount of the blades meet the requirements of a database is verified, in the automatic polishing test production verification process, the blades are continuously processed according to Cpk calculation specifications, the polishing removal amount is counted, the capability index Cpk of the automatic polishing process is calculated to be more than 1.33, and under the same fault grade, the standard deviation of the polishing removal amount can be 0.005mm. The reliability of the process parameter library is verified.
By using a control software system, parameters such as linear speed, feeding rate, polishing pressure and the like when the automatic polishing equipment polishes the blade can be controlled. When in formal processing, firstly, the removal quantity grade of the batch of blades is judged, then, the corresponding process database is called by equipment to carry out automatic polishing, an automatic polishing system can use the existing production execution management and control software system in the field, and is matched with automatic polishing equipment, the polishing and material removal of the fan rotor blades cannot exceed the upper limit of equipment control tolerance, removal quantity data can be counted periodically in the repairing process, the stability and the accuracy of the automatic polishing process can be fed back according to the removal quantity statistic analysis data, the process parameters under the grade, such as the linear speed v, the longitudinal feeding rate F and the polishing pressure F, of each blade are polished in sequence, the service life of an abrasive belt is monitored intelligently, and the replacement of the abrasive belt is reminded.
The foregoing is merely exemplary of the present invention, and the specific structures and features well known in the art are not described in any way herein, so that those skilled in the art will be able to ascertain all prior art in the field, and will not be able to ascertain any prior art to which this invention pertains, without the general knowledge of the skilled person in the field, before the application date or the priority date, to practice the present invention, with the ability of these skilled persons to perfect and practice this invention, with the help of the teachings of this application, with some typical known structures or methods not being the obstacle to the practice of this application by those skilled in the art. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the structure of the present invention, and these should also be considered as the scope of the present invention, which does not affect the effect of the implementation of the present invention and the utility of the patent.
Claims (8)
1. A method of polishing a fan rotor blade based on grading, comprising the steps of:
s1: detecting defect data of the surface of the fan rotor blade using a surface defect identification device;
s2: inquiring the acquired process parameter library, and determining the removal level corresponding to the defect data acquired in the step S1;
s3: inputting the removal quantity grade determined in the step S2 into a control software system, matching with polishing parameters of the corresponding removal quantity grade, and polishing the fan rotor blade in polishing equipment;
the process parameter library acquisition comprises the following steps:
s2-1: dividing the removal amount into a plurality of groups of grades by taking the maximum defect depth detected by the surface recognition equipment as an interval range of 0.03 mm;
s2-2: after a certain group of removal rate grades are selected, measuring the wall thickness reduction of each section of the fan rotor blade before and after polishing by using a measuring instrument to evaluate the polishing removal rate;
s2-3: testing the polishing removal quantity of each blade in the whole life cycle of a single abrasive belt, taking the constant polishing removal quantity as a target, and correcting each parameter of the polishing process in the whole life cycle of the abrasive belt;
s2-4: recording linear speed, feeding speed and polishing pressure parameters of the abrasive belt of the polishing equipment in the group of removal quantity grades;
s2-5: testing and recording the corresponding parameters of the residual removal level according to the steps;
s2-6: and selecting a fan rotor blade to carry out production verification of the removal quantity, and verifying whether the service life of the abrasive belt and the removal quantity of the fan rotor blade meet the requirements of a process parameter library.
2. A method of polishing a fan rotor blade based on grading as in claim 1, wherein: in S2-2, the wall thickness and the maximum wall thickness of the front edge and the rear edge of each section surface of the fan rotor blade are also required to be evaluated.
3. A method of polishing a fan rotor blade based on grading as in claim 1, wherein: in S2-2, the wall thickness of at least three sections of the upper, middle and lower sections of the fan rotor blade is measured, wherein the wall thickness of each section comprises a wall thickness at a fixed distance from the front edge, a wall thickness at a fixed distance from the rear edge and a maximum wall thickness.
4. A method of polishing a fan rotor blade based on grading as in claim 3, wherein: and (5) monitoring the thickness of the abrasive belt after each fan rotor blade is polished in the polishing process until the thickness of the abrasive belt is thinned to a thickness without material removing capability, and stopping polishing.
5. A method of polishing a fan rotor blade based on grading as in claim 1, wherein: in the process parameter library, the removal level is classified into three groups of levels.
6. The method for polishing a fan rotor blade based on grading as recited in claim 5, wherein three groups of removal amount grading ranges are: 0.01 mm-0.03 mm, 0.04 mm-0.06 mm, 0.07 mm-0.09 mm.
7. A method of polishing a fan rotor blade based on grading as in claim 1, wherein: the defect data includes depth and width data of the scratch.
8. A method of polishing a fan rotor blade based on grading as in claim 1, wherein: in S2-2, the measuring instrument is a three-coordinate measuring instrument.
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