Application of novel force control strategies to enhance robotic abrasive belt grinding quality of aero-engine blades

Xu, Xiaohu; Zhu, Dahu; Zhang, Haiyang; Yan, Shuicheng; Ding, Han

doi:10.1016/j.cja.2019.01.023

Cited by 104 publications

(31 citation statements)

References 37 publications

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“…Some related study has shown that the constant grinding force combined with the optimal process parameters is quite suitable for belt grinding of complex surfaces. 21,22,26,32 In the process of machining, the change of speed v s or v w does not adversely affect the surface of the workpiece while the change of F n will cause impact in the contact area, leaving large marks on the machined surface. The phenomenon of over- and under-cutting of the workpieces can also be avoided by a constant normal force.…”

Section: Constant Force Grindingmentioning

confidence: 99%

“…Keeping the contact force constant during machining can improve the dimensional precision, but also improve the surface quality. Xu et al 22 proposed a method of hybrid force-position control combined with PI/PD control in robotic abrasive belt grinding of complex geometries. The phenomena of over- and under-grinding was avoided, and Ra was reduced to half from an average value of 0.744 to 0.335 µm when the force control technology was applied.…”

Section: Constant Force Grindingmentioning

confidence: 99%

“…17–20 Some related study has shown that the constant grinding force combined with the optimal process parameters is quite suitable for belt grinding of complex surfaces. 21,22 Thus, in recent years, there are some research works done on how to achieve the desired force control. Cheng et al 23 investigated the contact force in micro-slot-grinding (MSG) of single-crystal sapphire and installed a dynamometer on a robot to monitor the contact force, but the force control technology was not applied.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Investigation of the effect of abrasive belt constant force grinding based on mechanical decoupling tool system

Guohong

Zhao

Wang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the abrasive belt grinding process, there are factors affecting the machining stability, efficiency, and quality. Based on the analysis of the grinding process, the normal force in the contact area between the abrasive belt and the workpiece is a major factor. By comparing constant force and non-constant force grinding, the results imply that keeping the grinding force constant will achieve desired material removal and better surface quality. The phenomenon of over- and under-cutting of the workpieces can also be avoided by a constant normal force. In this article, a controllable and flexible belt grinding mechanism accompanied with a mechanical decoupling control strategy is built and tested. Afterward, a detailed comparison is made between the traditional force-position coupling system and the proposed decoupling control system. The proposed control system suppresses the interference between the position and force control systems. The contact force is directly measured and controlled without detecting the position of other components in the tool system. The complexity of the control system is thereby reduced. Finally, several grinding experiments are carried out. The standard deviation and coefficient of variation of the measured normal force are kept within 0.25 and 0.02, respectively. The experiment results reveal that the mechanical decoupling system performs well in force control compared with the traditional force-position coupling system. In addition, the surface roughness Ra < 0.4 μm, the surface quality of the workpiece is improved significantly with the constant force controller.

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Section: Constant Force Grindingmentioning

confidence: 99%

Section: Constant Force Grindingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Investigation of the effect of abrasive belt constant force grinding based on mechanical decoupling tool system

Guohong

Zhao

Wang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Due to the large spread of the airfoil position in relation to the dovetail, the manual blade processing method has become very popular; however, it is associated with a number of problems with repeatability and ensuring occupational safety and health. The use of robotic stations [12,13] present a solution to this problem, due to the fact that such stations are more flexible than CNC machines. This applies both to flexibility in terms of physical characteristics and in terms of software capabilities.…”

Section: Introductionmentioning

confidence: 99%

“…The first way is to use flexible tools that would allow the machining system to automatically adapt to the blade. Belt grinders are the most popular solution in this area [12,13]. However, the tensioning system, vibrations, rapid wear, and the need to change the belt present numerous problems, which make it difficult to fully automate the process.…”

Section: Introductionmentioning

confidence: 99%

Device for Contact Measurement of Turbine Blade Geometry in Robotic Grinding Process

Szybicki

Burghardt

Kurc

et al. 2020

Sensors

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The article discusses the design, implementation, and testing of the accuracy of a measuring device used to measure the thickness of aircraft engine blades subjected to a robotic grinding process. The assumptions that the measuring device should meet were presented. The manufactured device was subjected to accuracy and repeatability tests using a standard workpiece. The analysis of research results proved that the measuring device exhibits an accuracy of one order of magnitude better than the accuracy required for blades. For control of the grinding process, the results should be perceived as appropriate. Then, the device was subjected to verification consisting in using it to measure the thickness of aircraft engine blades. The constructed device can be used, not only for inspection of final products, but also for control of the robotic grinding process because thanks to the output interface it can be used in the robotic station’s feedback loop.

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A prediction model of residual stress for belt‐grinding blade based on geometrical characteristic and progressive wear of abrasive grains

Wang

Lai

et al. 2022

Numerical Meth Engineering

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The formation mechanism of residual stress on the machined surface of belt grinding is sophisticated, and residual stress is an important factor affecting the fatigue life of aero‐engine blades. In this study, a prediction model of residual stress in a belt grinding blade is proposed with the geometrical characteristics and progressive wear of the grains as the research topic. By extracting the morphological features of abrasive belt, the residual stress based on different geometrical characteristics of grains (pyramidal, hexahedral, spherical, and conical belts) were investigated, and the optimal grain geometry was determined to be a uniformly arranged positive quadrilateral cone. Accordingly, a grinding experiment with a pyramidal belt was conducted to obtain an experienced model of the grain wear height. A numerical simulation model of the grain wear evolution under four wear states (no abrasion, early abrasion, middle abrasion, and late abrasion) was developed. Additionally, more detailed progressive wear of the abrasive grains was also applied to grind the entire profile of the complex curved blade. The residual stress on the blade surface was mainly compressive, and the surface stress values were distributed between −385 and −117 MPa with the service life of the pyramidal abrasive belt.

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Application of novel force control strategies to enhance robotic abrasive belt grinding quality of aero-engine blades

Cited by 104 publications

References 37 publications

Investigation of the effect of abrasive belt constant force grinding based on mechanical decoupling tool system

Investigation of the effect of abrasive belt constant force grinding based on mechanical decoupling tool system

Device for Contact Measurement of Turbine Blade Geometry in Robotic Grinding Process

A prediction model of residual stress for belt‐grinding blade based on geometrical characteristic and progressive wear of abrasive grains

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