CN116352560A - Engine blade grinding and polishing processing method based on industrial robot - Google Patents
Engine blade grinding and polishing processing method based on industrial robot Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
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- 238000007517 polishing process Methods 0.000 claims description 7
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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
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/14—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding turbine blades, propeller blades or 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
- B24B41/00—Component parts such as frames, beds, carriages, headstocks
- B24B41/06—Work supports, e.g. adjustable steadies
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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
- B24B49/12—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 involving optical means
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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
- B24B51/00—Arrangements for automatic control of a series of individual steps in grinding a workpiece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
- B25J11/005—Manipulators for mechanical processing tasks
- B25J11/0065—Polishing or grinding
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Robotics (AREA)
- Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
The invention discloses an engine blade grinding and polishing processing method based on an industrial robot, which comprises the following steps: designing and manufacturing a tool clamp; formulating an abrasive test qualification standard; the resilience force of the flexible mechanism is adjusted according to the profile condition of the blade and the thickness of the air inlet and outlet edges; assembling the blade according to the origin coordinates of the robot and planning a polishing path; performing simulation verification on the polishing track and the polishing gesture of the tool clamp and the robot; planning a motion trail of the robot; introducing digital analog, and designing a blade section to be detected and a detection height during blue light detection; setting basic polishing parameters to generate a polishing program; manually grabbing and debugging the blade; verifying a polishing program and adjusting a polishing angle; verifying the blue light detection device; performing rough polishing, semi-fine polishing and fine polishing on the profile of the blade; self-adaptive polishing is carried out on the inlet and exhaust edges of the blade; blue light is used for online detection on the air inlet and outlet sides of the blades; polishing the blade mounting plate; the blade is integrally polished.
Description
Technical Field
The invention belongs to the technical field of engine blade machining, and relates to an engine blade grinding and polishing machining method based on an industrial robot.
Background
Blades are key components of aircraft engines. The accuracy of the blades directly determines the performance, life and safety of the engine. At present, most of the blades are polished manually, the surface integrity and consistency of polished areas cannot be guaranteed due to the influence of manual operation, in addition, the continuously-rising labor cost is high, the high-tech workers are scarce, multiple working procedures in blade processing are circulated, parts of the blades still have the condition of damaging matrixes or blades, hidden hazards are brought to the quality of products and the processing cost, and meanwhile, the method is contrary to the current industrial development direction.
Therefore, the conventional processing technology is difficult to meet the requirements of product processing, and in order to improve the service life and reliability of engine parts, research on the polishing technology of the complex profile blade is urgently needed, and the quality and processing efficiency of the product are improved by the aid of related manufacturing technology and intelligent technology.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide the engine blade grinding and polishing processing method based on the industrial robot, which not only meets the precision and efficiency, but also greatly improves the consistency of products, greatly reduces the rejection rate and improves the processing environment.
The invention provides an engine blade grinding and polishing processing method based on an industrial robot, which comprises the following steps:
s1: designing and manufacturing a fixture clamp based on the CAD model of the blade and the set polishing area;
s2: making an abrasive test qualification standard according to the blade acceptance standard;
s3: the rebound force of the flexible mechanism of the main shaft for polishing the air inlet and outlet edges is adjusted in advance according to the profile condition of the blade and the thickness of the air inlet and outlet edges;
s4: establishing a machining coordinate system according to the origin coordinates of the robot, assembling the blade and planning a blade polishing path;
s5: establishing 1:1, the simulation environment carries out simulation verification on the polishing track and the gesture of the fixture clamp and the robot, and if a problem exists, the polishing path is readjusted;
s6: planning a motion trail of a robot, setting a transfer node in a robot control system and manually teaching;
s7: leading the assembled digital model and the robot polishing track into a robot control system, planning and designing a blade section and a detection height to be detected during blue light detection based on a theoretical digital model;
s8: setting basic polishing parameters, including: force, linear speed and feed speed, generating a polishing program;
s9: based on the coordinates obtained by simulation, the manual grabbing and debugging are carried out on the blade by matching with the real-time coordinate system feedback function of the robot;
s10: verifying a polishing program and adjusting a polishing angle;
s11: the robot carries out calibration of the blue light detection device through a calibration block carried by the robot;
s12: the robot performs rough polishing, semi-fine polishing and fine polishing on the profile of the blade;
s13: the robot uses a main shaft tool with a flexible mechanism to adaptively polish the inlet and exhaust edges of the blade;
s14: the robot uses a blue light detection device to detect the outline of the air inlet and outlet edges of the blades on line;
s15: the robot polishes the blade mounting plate;
s16: the robot lights the blade as a whole.
Further, in the step S1, a material of the fixture is selected according to the hardness comparison table in combination with the actual blade hardness, and the fixture is mounted at the tail end of the mechanical arm of the robot to clamp the blade.
Further, the step S2 specifically includes:
s201: selecting an abrasive according to the material of the blade;
s202: testing is carried out on the attenuation, the service life and the limit state of the abrasive during polishing.
Further, the step S4 specifically includes:
s401: assembling the blade, the tool clamp and the robot by using UG or Solidworks with the origin of the robot as the center, establishing a complete processing coordinate system with the origin of the robot as the center, and deriving an assembled digital model;
s402: and (5) importing the assembled digital-analog module into a Mastercam or a robotrmaster to program a grinding path, and generating the grinding path.
Further, the step S5 specifically includes:
and establishing a simulation environment according to a tool module used for blade processing, importing a previously programmed blade polishing path and assembled blade digital-analog into the simulation environment, simulating a robot polishing process, simulating and verifying a robot polishing track, and readjusting the blade polishing path if a problem exists.
Further, the step S6 specifically includes:
before approaching the polishing point, the robot runs to a designated node, gradually approaches the target position through a plurality of nodes, and the transfer node compares the coordinate calculated according to simulation software with the coordinate reached by the robot during actual processing, and corrects errors through repeated iteration to achieve high repeated positioning accuracy; if the actual coordinates displayed on the Fanuc robot demonstrator deviate from the actual coordinates in the simulation software, the coordinates of the middle point are adjusted by manual teaching.
Further, the step S8 specifically includes:
s801: knowing the removal amount of single polishing during manual polishing, and simultaneously calculating the wire outlet speed by referring to the rotating speed of a polishing tool, and applying the wire outlet speed to primary debugging of a program;
s802: when the air inlet and the air outlet are processed, the optimal processing tangential angle is calculated; when there are three tangents:
when there are four tangents:
wherein θ 1 Represents the first tangential angle, θ 2 Represents the second tangential angle, θ 3 Represents the third tangential angle, θ 4 Representing a fourth tangential angle; the first tangential angle is 25-40 degrees, and the last tangential angle is less than 90 degrees.
Further, the step S10 specifically includes:
step S1001: the robot obtains a blue light detection angle and a motion track of the robot when carrying out blue light detection according to a blade theoretical model, and if a torsion angle exists between a substituted processed blade and the theoretical model, a robot control system calculates a new grinding and polishing tool vector so as to adjust a polishing gesture;
step S1002: if the situation of unsuitable posture or interference occurs during blade grinding and polishing processing, a robot control system calculates a new grinding and polishing tool vector, and then adjusts the polishing posture.
Further, in the step S10, a new polishing tool vector after rotation is calculated according to the following formula:
n'＝n×cosα+(n×t')×t'×(1-cosα)+t'×sinα
wherein n is a normal vector of a machining point position, namely a grinding and polishing tool vector, n is perpendicular to a tangential vector t in the profile direction of the blade, and when the gesture of the robot is adjusted during grinding and polishing, the angle alpha is dynamically adjusted by winding the tangential vector t and combining a right-hand method to obtain the adjusted gesture of the robot; t 'is the tangential vector after unitization and n' is the new polishing tool vector after rotation.
Further, the step S14 specifically includes:
s1401: acquiring an actual contour of a current blade, comparing the actual contour with a theoretical contour, and calculating a difference region between the actual contour and the actual blade after fitting;
s1402: judging whether the difference area is within a tolerance zone according to a set tolerance, and obtaining whether a processing conclusion is obtained;
s1403: according to a preset machining tangential angle, a machining angle suitable for the current blade is calculated and selected, and meanwhile, a matched feeding speed is calculated;
s1404: after finishing one round of processing, detecting again, and jumping out of circulation if the blade is completely qualified; if the blade is unqualified, firstly judging whether the machining cycle times are set, if the machining cycle times are greater than 1, continuing to operate the steps from S1401 to S1403 until the blade is machined to be in a qualified state or the upper limit of the cycle is reached.
The engine blade grinding and polishing processing method based on the industrial robot has the following beneficial effects:
compared with the traditional grinding and polishing blade, the grinding and polishing process based on the industrial robot has the characteristics of high automation degree, high stability, high flexibility, online detection and the like, the consistency performance of products is reliably ensured, the processing quality and efficiency are improved, the rejection rate is reduced, the existing processing mode is greatly improved, the labor force is liberated, meanwhile, the humanized visual interface reduces the programming difficulty, and the accuracy of the program and the understanding of programmers on the blade process are improved. In addition, the invention is not only limited to the polishing and grinding processing of a certain blade, is suitable for processing parts with other various complex curved surfaces, and can realize the automatic processing of new parts by off-line programming through CAD digital and analog of the parts.
Drawings
Fig. 1 is a flow chart of an engine blade grinding and polishing processing method based on an industrial robot.
Detailed Description
As shown in fig. 1, the engine blade grinding and polishing processing method based on the industrial robot comprises the following steps:
s1: designing and manufacturing a fixture clamp based on the CAD model of the blade and the set polishing area;
the special fixture based on the CAD model design of the blade is an important step in the whole process, and the fixture is arranged at the tail end of a mechanical arm of a robot so as to clamp the blade. The stable clamping can be attached to a path designed by a theoretical model and a machining gesture calculated by a robot to the greatest extent, so that the difficulty of later fine adjustment is greatly reduced, and the product quality in mass production is improved. In addition, the hardness of the blade clamping surface needs to be known in advance, so that proper fixture materials can be selected according to a hardness comparison table, and the blade is prevented from being clamped.
S2: and (5) formulating an abrasive test qualification standard according to the blade acceptance standard. The shape selection of the abrasive is directly related to the polishing and grinding result of the blade, and before determining that one abrasive is the abrasive which can be used for final batch production, the abrasive needs to be subjected to life test, extreme heat temperature test, attenuation test and visual surface evaluation, and the removal amount of the abrasive also needs to be selected according to the average removable allowance of the blade. The step S2 specifically comprises the following steps:
s201: selecting an abrasive according to the material of the blade;
such as: the titanium alloy is processed by using a high-temperature resistant ceramic material or a silicon carbide material winding wheel with a special process, and the high-temperature alloy can be a superposition wheel made of aluminum oxide according to the blade removal requirement.
S202: testing is carried out on the attenuation, the service life and the limit state of the abrasive during polishing.
The test contents include, but are not limited to, the difference between the removal distances of the first blade and the last blade of the abrasive being polished exceeding 20%, whether the abrasive is heated and disintegrated in the unopened state of the robot air-cooling system, whether new processing marks appear on the polished surface, visual effects on the polished surface of the blade, and the like.
S3: the rebound force of the flexible mechanism of the main shaft for polishing the air inlet and outlet edges is adjusted in advance according to the profile condition of the blade and the thickness of the air inlet and outlet edges;
when the device is specifically implemented, the polishing main shaft with the blade inlet and exhaust edges adopts a floating mode, and when in feeding, if the pressure applied by the robot exceeds the preset main shaft resilience force, the main shaft can automatically return, so that the polishing cutter is self-adaptively attached to the surface of a part, and damage to the blade during feeding is avoided. The common rebound force is 13.5 N+/-10%, and the rebound force can be properly reduced by thinner blades.
S4: the method comprises the steps of establishing a machining coordinate system according to origin coordinates of a robot, assembling a blade and planning a blade polishing path, wherein the step S4 specifically comprises the following steps:
s401: assembling the blade, the tool clamp and the robot by using UG or Solidworks with the origin of the robot as the center, establishing a complete processing coordinate system with the origin of the robot as the center, and deriving an assembled digital model;
s402: importing the assembled digital analog into a Mastercam or a robotrmaster to program a polishing path, and generating a polishing path; during programming, attention is paid to the influence of surface UV rays on the gesture of the robot, and meanwhile, the polishing areas are separately programmed, so that the polishing programming is convenient.
S5: establishing 1:1, the simulation environment carries out simulation verification on the polishing track and the gesture of the fixture clamp and the robot, if the polishing path is readjusted due to a problem, the step S5 specifically comprises the following steps:
and establishing a simulation environment according to a tool module used for blade processing, importing a previously programmed blade polishing path and assembled blade digital-analog into the simulation environment, simulating a robot polishing process, simulating and verifying a robot polishing track, and readjusting the blade polishing path if a problem exists.
S6: planning a robot motion trail, setting a transfer node in a robot control system and manually teaching, wherein the step S6 specifically comprises the following steps:
planning the robot trajectory includes how the robot approaches the machining point after gripping the blade, but in the direct approach process, the robot may deviate from the ideal position coordinates due to very fine shake or offset, and may also cause excessive machining differences between blades. Therefore, in order to ensure the accuracy of the robot reaching the processing position, a plurality of transfer nodes are added in the middle of a path of the robot, the robot sequentially moves to the designated node before approaching the polishing point, the designated node gradually approaches the target position through the plurality of nodes, the transfer nodes compare the coordinates calculated according to the simulation software with the coordinates reached by the robot during actual processing, and the error is corrected through repeated iterations so as to achieve high repeated positioning accuracy. The transfer node can adjust specific coordinates according to own requirements, and the difference value between the actual coordinates and the calibrated transfer node coordinates can be properly adjusted during the test.
If the actual coordinates displayed on the Fanuc robot demonstrator deviate from the actual coordinates in the simulation software, the coordinates of the middle point are adjusted by manual teaching.
S7: leading the assembled digital model and the robot polishing track into a robot control system, planning and designing a blade section and a detection height to be detected during blue light detection based on a theoretical digital model;
when the detected blade section is set, the blade section position is required to be set according to the calibration in the blade technological rule, and the distance in the Z direction is required to be converted after the X, Y axis is fixed due to different reference origins, specifically referring to the following expression:
z'＝t+a+A i
wherein z' is the cross-section distance from the origin coordinate of the robot to the cross-section to be detected, and t is the projection distance from the original reference coordinate of the blade to the front panel of the robot. a is the distance from the digital-analog origin of blade assembly to the front panel of the sixth joint of the robot. A is that i And i is the serial number of the detection section for the height from the blade reference coordinate in the blade digital model to each section to be detected.
S8: setting basic polishing parameters, including: the force, the linear speed and the feeding speed generate a polishing program, and the step S8 specifically comprises:
s801: knowing the removal amount of single polishing during manual polishing, calculating the line-out speed by referring to the rotating speed of a polishing tool, and applying the line-out speed to program preliminary debugging, wherein the relationship between the line-out speed and the rotating speed is as follows:
v＝2πr×n
where v denotes a linear velocity, r denotes a radius, and n denotes a rotational speed, respectively.
S802: when the air inlet and the air outlet are processed, the optimal processing tangential angle is calculated;
when there are three tangents:
when there are four tangents:
wherein θ 1 Represents the first tangential angle, θ 2 Represents the second tangential angle, θ 3 Represents the third tangential angle, θ 4 Representing a fourth tangential angle; the angles of the first tangent line and the last tangent line are judged according to the actual grinding angle and the requirement of the blade. The first tangential angle is between 25 and 40 degrees, and the thinner the blade inlet and exhaust edges are, the more the angle approaches 40 degrees, and the more the angle approaches 25 degrees conversely. The last tangential angle is smaller than 90 degrees, and the angle approaches 90 degrees under the condition of not interfering with polishing positions (air inlet and outlet edges) according to the blade shape and the size of the grinding wheel. 0 ° is the normal vector of the blade contact surface.
S9: based on the coordinates obtained by simulation, the manual grabbing and debugging are carried out on the blade by matching with the real-time coordinate system feedback function of the robot;
during specific implementation, the robot is manually subjected to grabbing teaching, and during grabbing, the Fanuc robot demonstrator can call the coordinates of the real-time joint coordinate system. The robot coordinates calculated in the simulation software can be compared with the robot coordinates in the teaching, and the coordinates in the simulation software can be adjusted to achieve automatic calibration of coordinate matching, so that the possible deviation in the grabbing link is reduced as much as possible, and preparation is made for subsequent processing.
S10: the sanding procedure was verified and the sanding angle was adjusted. During verification of the machining program, partial grinding or unsatisfactory visual surface may occur, and at this time, an adjusted grinding and polishing tool vector needs to be obtained through calculation, and the posture or polishing angle of the robot needs to be adjusted through the brain wave software, which includes: but not limited to, six axis offset or rotation of the robot. The step S10 specifically includes:
step S1001: the robot obtains a blue light detection angle and a motion track of the robot when carrying out blue light detection according to a blade theoretical model, and if a torsion angle exists between a substituted processed blade and the theoretical model, a robot control system calculates a new grinding and polishing tool vector so as to adjust a polishing gesture;
step S1002: if the situation of unsuitable posture or interference occurs during blade grinding and polishing processing, a robot control system calculates a new grinding and polishing tool vector, and then adjusts the polishing posture.
In practice, the new polishing tool vector after rotation is calculated according to the following formula:
n'＝n×cosα+(n×t')×t'×(1-cosα)+t'×sinα
wherein n is a normal vector of a machining point position, namely a grinding and polishing tool vector, n is perpendicular to a tangential vector t in the profile direction of the blade, and when the gesture of the robot is adjusted during grinding and polishing, the angle alpha is dynamically adjusted by winding the tangential vector t and combining a right-hand method to obtain the adjusted gesture of the robot; t 'is the tangential vector after unitization and n' is the new polishing tool vector after rotation.
S11: the robot carries out calibration of the blue light detection device through a calibration block carried by the robot;
in the grinding and polishing process, the robot needs to clamp the blade and move to the blue light detection device for detection, and the blue light detection device needs to verify in advance so as to ensure that the detected profile sections are matched and accord with the actual allowance of the current blade during detection. Meanwhile, when the detection needs to be confirmed, the blade cannot collide with or interfere with the blue light detection device, and if interference and other conditions are met, the gesture of the robot needs to be properly adjusted.
During implementation, the robot moves to a blue light detection station, the blue light detection device detects blue light of a calibration block carried by the robot, and calibration of the blue light detection device is achieved by comparing the theoretical outline of the calibration block with the actual outline of the calibration block detected by the blue light.
S12: the robot performs rough polishing, semi-fine polishing and fine polishing on the profile of the blade;
in semi-finish polishing, it is required to ensure that the surface of the blade has no obvious polishing mark or defect and the surface roughness after polishing is not lower than Ra0.6.
When the blade is polished precisely, the surface of the blade needs to be ensured to have no polishing trace, the surface of the blade is bright, no visual defect exists, the blade can accept that the edge of the air inlet and outlet side has a fine cutter trace and is reserved for the next working procedure, and the roughness is not lower than Ra0.4.
S13: the robot uses a main shaft tool with a flexible mechanism to adaptively polish the inlet and exhaust edges of the blade;
in specific implementation, the robot control system acquires the actual profile of the current blade, compares the actual profile with the theoretical profile, and calculates a difference region with the actual blade after fitting. And judging whether the difference area is within a tolerance zone according to the set tolerance, and obtaining whether the processing conclusion is reached. And then calculating the machining angle suitable for the current blade according to the preset machining tangential angle, and simultaneously calculating the matched feeding speed to finish self-adaptive grinding.
S14: the robot uses the blue light detection device to detect the outline of the air inlet and outlet edges of the blades on line, and the step S14 specifically comprises:
s1401: acquiring an actual contour of a current blade, comparing the actual contour with a theoretical contour, and calculating a difference region between the actual contour and the actual blade after fitting;
s1402: judging whether the difference area is within a tolerance zone according to a set tolerance, and obtaining whether a processing conclusion is obtained;
s1403: according to a preset machining tangential angle, a machining angle suitable for the current blade is calculated and selected, and meanwhile, a matched feeding speed is calculated;
s1404: after finishing one round of processing, detecting again, and jumping out of circulation if the blade is completely qualified; if the blade is unqualified, firstly judging whether the machining cycle times are set, if the machining cycle times are greater than 1, continuing to operate the steps from S1401 to S1403 until the blade is machined to be in a qualified state or the upper limit of the cycle is reached.
S15: the robot polishes the blade mounting plate;
when grinding the mounting plate, the polishing of the blade mounting plate and the adapter is typically accomplished with two different grinding wheels, which may have different sizes and shapes depending on the area being treated by the polishing process. The rough polishing grinding wheel is generally selected from 3M Rapid Cut 7XCRS. According to the feeding amount and the rotating speed, the grinding wheel can remove blade materials of 0.025mm to 0.050mm, and after rough polishing, the grinding wheel of the model 3M Scotch Brite Light Deburring Wheel8SF grinding wheel sample can be used for fine polishing so as to improve the surface quality and the attractive effect of the flange plate.
Polishing of the mounting plate is accomplished by an angled grinding wheel. The part with the angle on the grinding wheel can be in flat contact with the mounting plate, and the robot throws and grinds the surface of the flange plate in a reciprocating mode at a preset distance between the mounting plate and the switching part. The polishing of the surface over this distance is accomplished by the polishing process of the transition portion.
S16: the robot lights the blade as a whole.
And finally, when the blade is polished, the main purpose is to fuse the multiple sections of polished areas of the blade together through a grinding wheel or an extremely fine abrasive belt, thereby improving the visual effect and ensuring that the final roughness is not lower than Ra0.4.
The foregoing description of the preferred embodiments of the invention is not intended to limit the scope of the invention, but rather to enable any modification, equivalent replacement, improvement or the like to be made without departing from the spirit and principles of the invention.
Claims (10)
1. The engine blade grinding and polishing processing method based on the industrial robot is characterized by comprising the following steps of:
s1: designing and manufacturing a fixture clamp based on the CAD model of the blade and the set polishing area;
s2: making an abrasive test qualification standard according to the blade acceptance standard;
s3: the rebound force of the flexible mechanism of the main shaft for polishing the air inlet and outlet edges is adjusted in advance according to the profile condition of the blade and the thickness of the air inlet and outlet edges;
s4: establishing a machining coordinate system according to the origin coordinates of the robot, assembling the blade and planning a blade polishing path;
s5: establishing 1:1, the simulation environment carries out simulation verification on the polishing track and the gesture of the fixture clamp and the robot, and if a problem exists, the polishing path is readjusted;
s6: planning a motion trail of a robot, setting a transfer node in a robot control system and manually teaching;
s7: leading the assembled digital model and the robot polishing track into a robot control system, planning and designing a blade section and a detection height to be detected during blue light detection based on a theoretical digital model;
s8: setting basic polishing parameters, including: force, linear speed and feed speed, generating a polishing program;
s9: based on the coordinates obtained by simulation, the manual grabbing and debugging are carried out on the blade by matching with the real-time coordinate system feedback function of the robot;
s10: verifying a polishing program and adjusting a polishing angle;
s11: the robot carries out calibration of the blue light detection device through a calibration block carried by the robot;
s12: the robot performs rough polishing, semi-fine polishing and fine polishing on the profile of the blade;
s13: the robot uses a main shaft tool with a flexible mechanism to adaptively polish the inlet and exhaust edges of the blade;
s14: the robot uses a blue light detection device to detect the outline of the air inlet and outlet edges of the blades on line;
s15: the robot polishes the blade mounting plate;
s16: the robot lights the blade as a whole.
2. The method for polishing and machining an engine blade based on an industrial robot according to claim 1, wherein in the step S1, a material of a fixture is selected according to a hardness comparison table in combination with an actual blade hardness, and the fixture is mounted at the end of a mechanical arm of the robot to clamp the blade.
3. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S2 is specifically:
s201: selecting an abrasive according to the material of the blade;
s202: testing is carried out on the attenuation, the service life and the limit state of the abrasive during polishing.
4. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S4 is specifically:
s401: assembling the blade, the tool clamp and the robot by using UG or Solidworks with the origin of the robot as the center, establishing a complete processing coordinate system with the origin of the robot as the center, and deriving an assembled digital model;
s402: and (5) importing the assembled digital-analog module into a Mastercam or a robotrmaster to program a grinding path, and generating the grinding path.
5. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S5 is specifically:
and establishing a simulation environment according to a tool module used for blade processing, importing a previously programmed blade polishing path and assembled blade digital-analog into the simulation environment, simulating a robot polishing process, simulating and verifying a robot polishing track, and readjusting the blade polishing path if a problem exists.
6. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S6 is specifically:
before approaching the polishing point, the robot runs to a designated node, gradually approaches the target position through a plurality of nodes, and the transfer node compares the coordinate calculated according to simulation software with the coordinate reached by the robot during actual processing, and corrects errors through repeated iteration to achieve high repeated positioning accuracy; if the actual coordinates displayed on the Fanuc robot demonstrator deviate from the actual coordinates in the simulation software, the coordinates of the middle point are adjusted by manual teaching.
7. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S8 is specifically:
s801: knowing the removal amount of single polishing during manual polishing, and simultaneously calculating the wire outlet speed by referring to the rotating speed of a polishing tool, and applying the wire outlet speed to primary debugging of a program;
s802: when the air inlet and the air outlet are processed, the optimal processing tangential angle is calculated; when there are three tangents:
when there are four tangents:
wherein θ 1 Represents the first tangential angle, θ 2 Represents the second tangential angle, θ 3 Represents the third tangential angle, θ 4 Representing a fourth tangential angle; the first tangential angle is 25-40 degrees, and the last tangential angle is less than 90 degrees.
8. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S10 is specifically:
step S1001: the robot obtains a blue light detection angle and a motion track of the robot when carrying out blue light detection according to a blade theoretical model, and if a torsion angle exists between a substituted processed blade and the theoretical model, a robot control system calculates a new grinding and polishing tool vector so as to adjust a polishing gesture;
step S1002: if the situation of unsuitable posture or interference occurs during blade grinding and polishing processing, a robot control system calculates a new grinding and polishing tool vector, and then adjusts the polishing posture.
9. The industrial robot-based engine blade grinding and polishing method according to claim 8, wherein the new polishing tool vector after rotation is calculated according to the following formula in step S10:
n'＝n×cosα+(n×t')×t'×(1-cosα)+t'×sinα
wherein n is a normal vector of a machining point position, namely a grinding and polishing tool vector, n is perpendicular to a tangential vector t in the profile direction of the blade, and when the gesture of the robot is adjusted during grinding and polishing, the angle alpha is dynamically adjusted by winding the tangential vector t and combining a right-hand method to obtain the adjusted gesture of the robot; t 'is the tangential vector after unitization and n' is the new polishing tool vector after rotation.
10. The industrial robot-based engine blade grinding and polishing method according to claim 1, wherein the step S14 is specifically:
s1401: acquiring an actual contour of a current blade, comparing the actual contour with a theoretical contour, and calculating a difference region between the actual contour and the actual blade after fitting;
s1402: judging whether the difference area is within a tolerance zone according to a set tolerance, and obtaining whether a processing conclusion is obtained;
s1403: according to a preset machining tangential angle, a machining angle suitable for the current blade is calculated and selected, and meanwhile, a matched feeding speed is calculated;
s1404: after finishing one round of processing, detecting again, and jumping out of circulation if the blade is completely qualified; if the blade is unqualified, firstly judging whether the machining cycle times are set, if the machining cycle times are greater than 1, continuing to operate the steps from S1401 to S1403 until the blade is machined to be in a qualified state or the upper limit of the cycle is reached.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117206989A (en) * | 2023-11-09 | 2023-12-12 | 泉州华中科技大学智能制造研究院 | Blade abrasive belt grinding method based on 3D vision online measurement technology |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117206989A (en) * | 2023-11-09 | 2023-12-12 | 泉州华中科技大学智能制造研究院 | Blade abrasive belt grinding method based on 3D vision online measurement technology |
| CN117206989B (en) * | 2023-11-09 | 2024-04-16 | 泉州华中科技大学智能制造研究院 | Blade abrasive belt grinding method based on 3D vision online measurement technology |
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