A small-sized flexible abrasive tool specially used for grinding and polishing areas prone to interference and its preparation method

Abstract

The present invention provides a small-sized flexible abrasive tool specifically designed for polishing areas prone to interference, and a method for manufacturing the same. The small, flexible abrasive tool comprises a connector, an elastic base, and an abrasive layer, the connector, elastic base, and abrasive layer being coaxial. The connector comprises a spindle and a threaded tube. The abrasive layer is made of a highly flexible electroplated abrasive belt, and the elastic base is made of rubber. The threaded tube, abrasive layer, and elastic base are vulcanized and bonded together to form a single unit. This small-sized, flexible abrasive tool specifically designed for polishing areas prone to interference features a tightly integrated structure. During precision machining, it can adaptively conform to the complex curved surfaces of the entire blade disk, improving both machining quality and efficiency.

Description

Technical Field

[0001] The invention relates to a small-sized flexible grinding tool specially used for grinding and polishing an easily-interferenced area and a manufacturing method thereof, belonging to the field of blade disc grinding and polishing. Background Art

[0002] Aircraft engine blisks are complex and require limited space. Currently, manual grinding and polishing are often required, resulting in extremely low processing efficiency, poor quality consistency, and a high risk of defects such as over-grinding and surface scratches. Using small, flexible grinding and polishing tools combined with robotics is a promising approach.

[0003] In addition, the curvature of the blade disk varies in a complex manner. Existing elastic grinding tools mostly fit the workpiece by micro-deformation of the elastic matrix, which makes it difficult to meet the requirements of processing two or more surfaces with large curvature changes. Therefore, if there is a more flexible grinding and polishing tool that can adaptively deform when the robot contacts the workpiece in different postures to adapt to the processing requirements of two or more complex surfaces, it will be beneficial to improve processing quality and production efficiency. Summary of the Invention

[0004] The purpose of the present invention is to provide a small-sized flexible abrasive tool specially used for grinding and polishing areas prone to interference, which is characterized by comprising a connector, an elastic base and an abrasive layer.

[0005] The upper end of the elastic base is a truncated cone-shaped structure, and the lower end is an outward extending portion. The outward extending portion forms a disc-shaped structure surrounding the bottom of the truncated cone-shaped structure.

[0006] The upper end of the truncated cone-shaped structure is connected to the connector.

[0007] The abrasive layer is located on the lower surface of the elastic base.

[0008] The abrasive layer is annular and comprises a plurality of annular abrasive sheets attached to the lower end surface of the elastic base. The abrasive sheets are a sanding belt with metal nickel and abrasive grains deposited on a conductive fiber mesh.

[0009] Furthermore, the connector includes a main shaft body whose upper end is connected to the machining equipment. The lower end of the main shaft body is a threaded pipe section with external threads. The threaded pipe section is connected to the elastic base.

[0010] Furthermore, the threaded pipe section is made of metal material, the elastic matrix is made of rubber material, and the threaded pipe, the abrasive layer and the elastic matrix are bonded into a whole during the vulcanization process.

[0011] Furthermore, the upper surface and / or lower surface of the structure has a plurality of annular grooves.

[0012] Furthermore, the truncated cone-shaped structure, the disk-shaped structure and each annular groove are coaxial.

[0013] Furthermore, the axial cross-section of the annular groove is semicircular.

[0014] Furthermore, the surface of the disk-shaped structure is a plane or a conical surface. When the surface of the disk-shaped structure is a plane, the axis of the truncated cone-shaped structure is perpendicular to the surface of the disk-shaped structure. When the surface of the disk-shaped structure is a conical surface, the angle between the generatrix of the conical surface and the axis of the truncated cone-shaped structure is between 70° and 90°.

[0015] Furthermore, the abrasive sheet is composed of a plurality of abrasive grains, a conductive fiber mesh and a polyester fiber cloth substrate.

[0016] Furthermore, a mixture of metallic nickel and abrasive particles is deposited on one surface of the conductive fiber mesh by electroplating, and the other surface of the conductive fiber mesh is attached to the surface of the polyester fiber cloth substrate.

[0017] The present invention claims protection for a method for manufacturing a small-sized flexible abrasive tool specifically designed for polishing areas prone to interference, characterized in that: a raw rubber sheet is used as the raw material for the elastic base. During the molding of the elastic base, a connector, an abrasive layer, and rubber particles are placed in a mold. The mold is then placed in a vulcanizer for vulcanization, thereby molding the elastic base. The threaded tube section of the connector is positioned within the truncated cone-shaped structure and coaxially aligned, thereby integrating the connector and the elastic base. Simultaneously, the abrasive layer is bonded to the bottom of the elastic base, forming a single unit.

[0018] The technical effect of the present invention is unquestionable. The small-sized flexible abrasive tool specially used for grinding and polishing the interference-prone area is tightly integrated as a whole. During precision machining, when the connector (through the manipulator) drives the grinding head to contact the workpiece at different angles and contact forces, it can match the complex curved surface of the integral blade disk, thereby improving the machining quality and efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a partial cross-sectional view of the structural schematic diagram of the grinding tool of Example 1;

[0020] Figure 2 is a bottom view of the abrasive layer of the grinding tool of Example 1;

[0021] Figure 3 is a partial cross-sectional view of the structural schematic diagram of the grinding tool of Example 2;

[0022] Figure 4 is a bottom view of the abrasive layer of the grinding tool of Example 2;

[0023] Figure 5 is a sectional view of a front view of the abrasive tool of Example 3;

[0024] Figure 6 is a bottom view of the abrasive layer of the grinding tool of Example 3;

[0025] Figure 7 It is a schematic diagram of the abrasive layer structure. DETAILED DESCRIPTION

[0026] The present invention will be further described below with reference to the following examples, but it should not be understood that the scope of the present invention is limited to the following examples. Without departing from the above technical ideas of the present invention, various substitutions and modifications can be made according to common technical knowledge and customary means in the art, and all should be included in the scope of protection of the present invention.

[0027] Example 1:

[0028] A small-sized flexible abrasive tool specially used for grinding and polishing areas prone to interference, characterized by comprising a connector 1, an elastic base 2 and an abrasive layer 3.

[0029] The upper end of the elastic base 2 is a truncated cone-shaped structure 21 , and the lower end is an outwardly extending portion. The outwardly extending portion forms a disc-shaped structure 22 surrounding the bottom of the truncated cone-shaped structure 21 .

[0030] The upper end of the truncated cone-shaped structure 21 is connected to the connector 1 .

[0031] The abrasive layer 3 is located on the lower surface of the elastic base 2 .

[0032] The abrasive layer 3 is annular and includes a plurality of annular abrasive sheets 31 attached to the lower end surface of the elastic base 2. The abrasive sheets 31 are abrasive belts with metal nickel and abrasive grains deposited on a conductive fiber mesh.

[0033] The connector 1 includes a spindle 11, the upper end of which is connected to the machining equipment. When in use, the grinding head is first connected to the machining equipment (such as a robot) through the connector 11. According to the different curvatures of the blade surfaces to be machined, the appropriate grinding head contact angle and contact force are selected. The grinding head working surface contacts the workpiece to machine the workpiece surface.

[0034] Example 2:

[0035] The main structure of this embodiment is the same as that of embodiment 1. Furthermore, the lower end of the main shaft 11 is a threaded pipe section 12 with external threads. The threaded pipe section 12 is connected to the elastic base 2.

[0036] The threaded tube section 12 is made of metal, and the elastic base 2 is made of rubber. The abrasive layer 3 is composed of a highly flexible electroplated abrasive belt. The threaded tube 12 and abrasive layer 3 are bonded together during the vulcanization process of the elastic base 2, forming a tight, integrated unit. Because the electroplated abrasive belt is much more flexible than the rubber elastic base, the abrasive layer deforms accordingly. The bottom surface of the elastic base is preset to be either a flat surface or a slightly inclined surface, depending on the processing scenario. When the connector drives the grinding head into vertical contact with the workpiece, the grinding head's working surface corresponds to the entire bottom surface of the elastic base, leveraging the elastic base's flexibility to adaptively machine flat or slightly curved surfaces. When the connector drives the grinding head into side contact with the workpiece, the thin outer surface of the elastic base will undergo a certain degree of elastic bending, further causing warping and driving the abrasive layer to adaptively machine surfaces with greater curvature. The flexibility of the elastic base's outer surface can be further increased by adding appropriate grooves to the bottom of the elastic base and by extending the flexible electroplated abrasive belt appropriately beyond the outer surface of the elastic base to enhance the grinding head's flexible machining capabilities. Therefore, when the connector drives the grinding head to contact the workpiece at different angles and contact forces, the bottom of the elastic base conforms to the shape of the workpiece contact area and drives the abrasive layer to adaptively deform, thereby realizing grinding and polishing of two or more curvature surfaces.

[0037] The upper surface and / or lower surface of the truncated cone-shaped structure 22 has a plurality of annular grooves 221. The truncated cone-shaped structure 21, the disc-shaped structure 22 and each annular groove 221 are coaxial. The axial cross-section of the annular groove 221 is semicircular.

[0038] Example 3:

[0039] The main structure of this embodiment is the same as that of embodiment 1. Furthermore, the diameter of the upper bottom surface of the truncated cone of the truncated cone-shaped structure 21 is 8-20 mm, the diameter of the lower bottom is 15-30 mm, and the height is 5-20 mm. The outer diameter of the ring is 15-50 mm, the inner diameter is 5-20 mm, and the thickness is 3-6 mm.

[0040] The surface of the disk-shaped structure 22 is a plane or a conical surface.

[0041] When the surface of the disk-shaped structure 22 is a plane, the axis of the truncated cone-shaped structure 21 is perpendicular to the surface of the disk-shaped structure 22 .

[0042] When the surface of the disk-shaped structure 22 is a conical surface, the angle between the generatrix of the conical surface and the axis of the truncated cone-shaped structure 21 is between 70° and 90°.

[0043] The two surfaces of the disc-shaped structure 22 are distributed with a plurality of semicircular grooves, which are arranged in a plurality of concentric circular arrays on the disc-shaped structure 22. The number of grooves is 0-5 (optionally none), and the spacing between adjacent grooves can be evenly distributed and can be 1-10 mm.

[0044] The abrasive layer 3 is composed of a plurality of annular abrasive sheets. The abrasive sheets 31 are arranged in a plurality of concentric circles and are distributed at the bottom of the elastic base ring.

[0045] Example 3:

[0046] The main structure of this embodiment is the same as that of embodiment 1. Furthermore, the abrasive layer 3 is annular with an inner diameter of 5-20 mm and an outer diameter of 20-55 mm. The abrasive sheet 31 is composed of a plurality of abrasive grains 311, a conductive fiber mesh 312 and a polyester fiber cloth substrate 313. In the embodiment, the abrasive sheet 3 is punched out from a shaped electroplated gauze, on which abrasive grain blocks 32 are regularly distributed. The abrasive grain blocks 32 are distributed in concentric circles on the electroplated gauze. There are gaps between each abrasive grain block 32 to facilitate chip removal and heat dissipation during the grinding and polishing process. The material of the abrasive grains is at least one of diamond and cubic boron carbide. By electroplating, a mixture of metallic nickel and abrasive grains is deposited on one surface of the conductive fiber mesh 312. The other surface of the conductive fiber mesh 312 is attached to the surface of the polyester fiber cloth substrate 313.

[0047] Example 4:

[0048] This embodiment is a method for manufacturing a small-sized flexible abrasive tool specifically for polishing areas prone to interference, as described in any one of Embodiments 1 to 3. It is characterized by using a raw rubber sheet as the raw material for the elastic base 2. During the molding of the elastic base 2, a connector 1, an abrasive layer 3, and rubber particles are placed in a mold. The mold is then placed in a vulcanizer for vulcanization, forming the elastic base 2. The threaded tube section 12 of the connector 1 is positioned within the truncated cone-shaped structure 21, coaxially, thereby integrating the connector 1 and the elastic base 2. Simultaneously, the abrasive layer 3 is bonded to the bottom of the elastic base 2, forming a single piece.

[0049] Example 5:

[0050] The main process of this embodiment is the same as that of Example 4. Furthermore, during the molding process, the raw rubber is first placed in an open mill for re-binding at a temperature of 70°C for 2 minutes. The raw rubber sheet is then cut into granules in preparation for insertion into the vulcanization mold. The electroplated abrasive belt is then punched into a ring state, and the non-abrasive surface is soaked in acetone. The outer wall of the threaded pipe is sandblasted. After the mold is preheated to the vulcanization temperature, the threaded pipe and the electroplated abrasive belt are positioned and loaded into the mold. The adhesive is evenly applied to the surface. The raw rubber particles are then filled into the mold. Finally, the mold is placed in a vulcanizer for vulcanization. The vulcanization time is 7 minutes, the vulcanization temperature is 145°C, and the apparent pressure is 9T.

[0051] The small-sized flexible abrasive tool specially used for polishing the easy-interference area prepared in this embodiment is as follows: Figure 1 As shown, the threaded tube 12, the abrasive layer 3 and the elastic base 2 are bonded into a whole during the vulcanization process.

[0052] In this embodiment, the diameter of the upper bottom surface of the truncated cone shaped structure 21 is 20 mm, the diameter of the lower bottom is 25 mm, and the height is 15 mm. The outer diameter of the ring is 45 mm, the inner diameter is 10 mm, and the thickness is 3 mm. The disc-shaped structure 22 is annular, and the angle between the outer extension of the ring and the axis is 90°. A plurality of grooves with a semicircular cross-section are symmetrically distributed on both sides of the end face of the ring, and the cross-sectional radius is 0.5 mm. The grooves are distributed in a plurality of concentric circular arrays on the ring, and the diameter of the distribution rings is greater than or equal to 25 mm. The number of grooves is 3, the spacing between adjacent grooves is 2.5 mm, and the cross-sectional diameter is 1 mm.

[0053] The abrasive layer 3 is annular with an inner diameter of 10 mm and an outer diameter of 45 mm. The abrasive layer 3 is composed of three annular abrasive sheets 31, which are arranged in a concentric array at the bottom of the elastic base ring. The abrasive sheets are punched from shaped electroplated gauze, on which abrasive particles 32 are regularly distributed. The abrasive particles 32 are distributed in concentric circles on the electroplated gauze, and the abrasive particles are made of diamond.

[0054] Example 6:

[0055] The main process of this embodiment is the same as that of embodiment 4. Furthermore, during molding, the elastic matrix 2 is mainly made of rubber, and its components include: the components of the rubber raw sheet: 78 parts of natural rubber with a Shore hardness of 40, 5 parts of sulfur, and 10 parts of kerosene.

[0056] First, the raw rubber is placed in an open mixing mill for re-sizing at 75°C for 3 minutes. The raw rubber is then cut into granules for insertion into the vulcanization mold. Next, the electroplated abrasive belt is punched into a ring shape, and the non-abrasive surface is soaked in acetone. The outer wall of the threaded tube is sandblasted. After the mold is preheated to the vulcanization temperature, the threaded tube and electroplated abrasive belt are positioned and loaded into the mold. Adhesive is evenly applied to the surface, and the raw rubber granules are then filled into the mold. Finally, the mold is placed in a vulcanizer for vulcanization for 7 minutes at 147°C and an apparent pressure of 8T.

[0057] The small-sized flexible abrasive tool specially made for grinding and polishing the interference-prone area is Figure 1 As shown, the elastic base 2, the threaded tube 11, and the abrasive layer 3 are integrally formed during the vulcanization process. The upper base diameter of the truncated cone structure 21 is 20 mm, the lower base diameter is 25 mm, and the height is 15 mm. The outer diameter of the ring is 20 mm, the inner diameter is 5 mm, and the thickness is 1 mm. The disc-shaped structure 22 is annular, with the angle between the outer extension of the ring and the axis being 90°. Semicircular grooves with a cross-sectional radius of 0.3 mm are symmetrically distributed on both sides of the ring end surface. The grooves are distributed in a concentric array on the ring, and the diameter of the distribution ring is equal to 25 mm. There is one groove, and the cross-sectional diameter is 1 mm.

[0058] The abrasive layer 3 is annular with an inner diameter of 5 mm and an outer diameter of 20 mm. The abrasive layer 3 is composed of two annular abrasive sheets, each of which is arranged in a concentric array at the bottom of the elastic base ring. The abrasive sheets 31 are stamped from a shaped electroplated gauze, on which abrasive particles 32 are regularly distributed. The abrasive particles 32 are arranged in concentric circles on the electroplated gauze. The abrasive particles are made of cubic boron nitride.

[0059] Example 6:

[0060] The main process of this embodiment is the same as that of embodiment 4. Furthermore, during molding, the elastic matrix is mainly made of rubber, and its components include: the components of the rubber raw sheet: 72 parts of natural rubber with a Shore hardness of 45, 5 parts of sulfur, and 12 parts of kerosene.

[0061] First, the raw rubber is placed in an open mixing mill for re-sizing at 75°C for 3 minutes. The raw rubber is then cut into granules for insertion into the vulcanization mold. Next, the electroplated abrasive belt is punched into a ring shape, and the non-abrasive surface is soaked in acetone. The outer wall of the threaded tube is sandblasted. After the mold is preheated to the vulcanization temperature, the threaded tube and electroplated abrasive belt are positioned and loaded into the mold. Adhesive is evenly applied to the surface, and the raw rubber granules are then filled into the mold. Finally, the mold is placed in a vulcanizer for vulcanization for 9 minutes at 145°C and an apparent pressure of 8T.

[0062] The small-sized flexible abrasive tool specially made for grinding and polishing the interference-prone area is Figure 1 As shown, the elastic base 2, the threaded tube 11, and the abrasive layer 3 are integrally formed during the vulcanization process. The upper base diameter of the truncated cone-shaped structure 21 is 20 mm, the lower base diameter is 25 mm, and the height is 15 mm. The disc-shaped structure 22 is annular with an outer diameter of 20 mm, an inner diameter of 5 mm, and a thickness of 1 mm. The angle between the outer extension of the ring and the axis is 82°.

[0063] The abrasive layer 3 is annular with an inner diameter of 5 mm and an outer diameter of 25 mm. The abrasive layer 3 is composed of a ring-shaped abrasive sheet. The abrasive sheets 31 are arranged in a concentric array at the bottom of the elastic base ring. The abrasive sheet is stamped from a shaped electroplated gauze. The electroplated gauze is regularly distributed with abrasive particles 32. The abrasive particles 32 are distributed in concentric circles on the electroplated gauze. The abrasive particles are made of diamond.

Claims

1. A small-sized flexible abrasive tool specially designed for grinding and polishing areas prone to interference, characterized in that : comprising a connector (1), an elastic base (2) and an abrasive layer (3); The upper end of the elastic base (2) is a truncated cone-shaped structure (21), and the lower end is an outwardly extending portion; the outwardly extending portion forms a disc-shaped structure (22) surrounding the bottom of the truncated cone-shaped structure (21); the upper surface and / or lower surface of the disc-shaped structure (22) have a plurality of annular grooves (221); The upper end of the truncated cone-shaped structure (21) is connected to the connector (1); The abrasive layer (3) is located on the lower surface of the elastic base (2); The abrasive layer (3) is annular and includes a plurality of annular abrasive sheets (31) attached to the lower end surface of the elastic base (2); the abrasive sheet (31) is a sanding belt in which metal nickel and abrasive grains are deposited on a conductive fiber mesh; the abrasive sheet (31) is composed of a plurality of abrasive grains (311), a conductive fiber mesh (312) and a polyester fiber cloth substrate (313).

2. The small-sized flexible abrasive tool for polishing easily interfered areas according to claim 1, characterized in that: The connecting body (1) comprises a main shaft body (11) whose upper end is connected to a machining device; the lower end of the main shaft body (11) is a threaded pipe section (12) with external threads; and the threaded pipe section (12) is connected to the elastic base (2).

3. The small-sized flexible abrasive tool for polishing easily interfered areas according to claim 2, characterized in that: The threaded pipe section (12) is made of metal material, and the elastic matrix (2) is made of rubber material; the threaded pipe section (12), the abrasive layer (3), and the elastic matrix (2) are bonded into a whole during the vulcanization process.

4. A small-sized flexible abrasive tool specially designed for grinding and polishing areas prone to interference according to claim 1 or 3, characterized in that: The axial cross-section of the annular groove (221) is semicircular.

5. A small-sized flexible abrasive tool specially designed for grinding and polishing areas prone to interference according to claim 1 or 3, characterized in that: The surface of the disc-shaped structure (22) is a plane or a conical surface.

6. A method for manufacturing a small-sized flexible abrasive tool for polishing an interference-prone area according to any one of claims 1 to 5, characterized in that: A rubber raw sheet is used as the raw material of the elastic matrix (2); when the elastic matrix (2) is formed, a connector (1), an abrasive layer (3) and rubber particles are placed in a mold; the mold is placed in a vulcanizer for vulcanization, so that the elastic matrix (2) is formed, and the threaded pipe section (12) of the connector (1) is located in the truncated cone structure (21) and is coaxial, that is, the connector (1) and the elastic matrix (2) are integrated; at the same time, the abrasive layer (3) is bonded to the bottom of the elastic matrix (2) as a whole.

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