Research On The Digital Prototype Modeling And Analysis Of Robotic Belt Grinding System For Blades

As development in technology, the aviation industry demands more engine with large thrust-weight ratio and high reliability. As a key component of aero engine, the dimensional accuracy and surface quality of blades has an important impact on engine performance. Blades are usually made of titanium alloys or superalloy which is difficult for milling and po-lishing. Most domestic enterprises use precision forging and manual polishing to finish blade manufacturing. The edge curvature of blades changing remarkably leads to the poor consis-tency and exceeding tolerance. It is difficult to meet the requirements of dimensional toler-ances and surface roughness.This paper developed a set of belt grinding system for blades which uses industrial ro-bots to finish blade grinding process automatically. This design of the belt grinding system consisted of the main institutions, industrial robots, laser tracker and control system. It was able to grind the small size blades under 50-100mm. For blade surface characteristics, it had a contact wheel with line replacement mechanism, which can change the wheel size depend-ing on the blade surface curvature. The blades had good contact with the wheel.This paper had research on the single particle grinding contact model to study the rela-tionship between removals and grinding parameters which determined the constant force grinding scheme. This paper designed the constant grinding compensation mechanism based on decoupling grinding force. It used the proportional valve and pressure sensors to achieve precise control of the grinding pressure to ensure the blade grinding surface quality. It used CATIA software to establish a digital prototype system for virtual assembling and spatial in-terference analysis. The result showed that the design of structure fits the requirement.After determining the dimensions of the components, this paper used ANS YS software to do the static and modal analysis of the key components.Then the results were used to op-timize the structure. The optimized result showed that the components met the requirements. The modal analysis of the optimized system obtained the first six natural frequencies and mode shapes. The modal result showed that the natural frequencies were away from the oper- ating frequency and system did not produce resonance.According to the robot motion model grinding process, this paper inverted the inverse solution for kinematics of belt grinding system in order to coordinate the robot posture ad-justment and the belt grinding compensation. ADAMS software was used for rotating eccen-tric vibration simulation. Each output point showed that vibration amplitude had significant impact in the process. This design met the vibration stability requirements for the accuracy.After the verification of digital prototype model, the result showed that the design of robotic belt grinding system structure was reasonable to meet the requirements of the blade grinding. The model can be provided for building the belt grinding system physical proto-types and finishing the blades grinding.