Study on robot automatic rounding for blade tip based on elastic grinding

Abstract

In order to achieve automatic rounding for blade tip, the study was conducted on small radius rounding based on elastic grinding, and a method of robot automatic grinding for small radius fillets of blade tip was proposed.The elastic grinding wheel with polyester ammonia fiber as substrate material is utilized the characteristics of elastic envelope deformation contact to grind sharp angles of blade tip to small radius fillets. Based on elastic contact theory and Preston equation, theoretical contact model and material removal model between grinding wheel and blade tip were established. Abaqus software was used to simulate and analyze the contact stress distribution and grinding removal amount. Simulation result demonstrates that the adaptive elastic contact deformation between grinding wheel and sharp angle of blade tip forms small surface envelope contact pattern and variable grinding removal amount, which can realize small radius fillet machining. Robot automatic rounding experiments for blade tip were conducted to verify feasibility and controllability of the machining method. The research results indicate that the elastic deformation of grinding wheel causes an arc-shaped contact stress distribution in the contact area of blade tip and abrasive coated on the substrate can achieve small radius fillet grinding. The combination of passive compliance formed by elastic grinding deformation and active force control is feasible to realize robot automatic rounding for small radius fillets, and the fillet radius can be controlled by changing grinding process parameters. Robot automatic rounding for blade tip is feasible, and machining process and accuracy are controllable and stable, which breaks through the traditional manual sandpaper grinding method and provides a new small radius fillet processing method.