Automation of the Edge Deburring Process and Analysis of the Impact of Selected Parameters on Forces and Moments Induced during the Process

Abstract

The article concerns the possibility of the automation and robotization of the process of deburring jet engine components. The paper presents the construction of a laboratory stand enabling the automation of selected production operations of typical low-pressure turbine blades. The work identifies important parameters and results of the technological process related to the removal of burrs that affect the exactness of the process. The results of the analysis of the impact of individual process parameters on the magnitude of forces and moments occurring during deburring were carried out and presented. The results of initial and detailed tests were presented. Based on the results obtained, it was noticed that doubling the rotational speed of the brush results in a linear increase in torque and an increase in the engagement of the detail in the disc brush, leading to a non-linear increase in torque. It has also been shown that with tool wear, the value of the torque generated by the rotating tool decreases. Based on the results of a comparison of manual and automated process and histogram analysis, results from an automated stand are centered more correctly inside of the required radius range. This means that the repeatability of the process is higher for an automated test stand, which is one of the key aspects of large-scale aviation component manufacturing. Additionally, it was confirmed by visual inspection that all burs had been removed correctly—the deburring operation for all tested work pieces was successful. Based on the results obtained, it was proven that introduction of an automated stand can improve working conditions (by the elimination of the progressive fatigue of employees and the possibility for injury) and allows for the elimination of the negative impact of the machining process on workers. Further areas in which the optimization of the process parameters of the edge deburring can be developed in order to reduce unit costs have also been indicated.

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

“…The material parameters and contact parameters are comprehensively outlined in Table 1 [14]. To ensure the simulation process reaches a steady state, the total (1) 4 Diagram of the collision between magnetic needle and workpiece simulation time is set to 2 s. The workpiece is segmented into three regions, designated as I, II, and III, based on the distance from the magnetic disc. Following the configuration of parameters in EDEM, the simulation of the machining process is depicted in Fig.…”

“…Because these defects typically exist at edges, ostia, and similar locations, the conventional methods are challenging to implement [3]. Manual scraping is often used, but the variations in the skill levels of personnel can lead to issues such as unstable processing quality and high scrap rates [4]. Hence, it is significant to achieve automated removal of edge defects and conduct in-depth analysis of their processing process [5].…”