Butt clamp rolling device and curved-surface thin-wall part surface microstructure rolling device and method

Abstract

In order to solve the technical problem that an existing surface microstructure rolling forming method and device cannot machine a microstructure on the surface of a curved-surface thin-wall blade in a narrow space such as a blisk blade, the invention provides a butt clamp rolling device and a curved-surface thin-wall part surface microstructure rolling device and method. The butt-clamping rolling device comprises the rolling unit and the clamp type clamping mechanism with the adjustable clamping force, the clamp type clamping mechanism is of a structure that the two supports are symmetrically distributed, it is guaranteed that the clamping force on the two sides is equal all the time, and micro-structure rollers at the front ends of the two supports can construct a micro-groove structure on the surface of the blade; meanwhile, a smooth roller wheel is used as a support to reduce blade deformation, and rolling strengthening is carried out; by means of the free combination of the microstructure roller and the smooth roller, on the basis that the deformation of the blade is small, double-face symmetrical rolling of the microstructure grooves, single-face rolling of the microstructure grooves and rolling strengthening are achieved, the aerodynamic performance and the anti-fatigue performance of the blade are improved, the service life of the blade is prolonged, and the production cost is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of metal surface microstructure processing. Background Art

[0002] At present, the compressor of aircraft engines is developing towards lighter weight, more compactness, higher load and higher aerodynamic efficiency. Research has found that the introduction of mesostructures such as grooves in multi-scale functional surface blades can greatly reduce the resistance of the blades, but it poses new challenges to the control of fatigue resistance during the manufacturing process.

[0003] Existing traditional surface microstructure processing methods include grinding technology, ultra-precision machining technology, femtosecond laser technology, etc. Grinding is limited by the narrow flow channel space of the blade disk, ultra-precision machining technology has low processing efficiency, and femtosecond laser processing is difficult to form the compressive stress state required by the design. Surface microstructure rolling forming technology, as a new type of surface microstructure plastic forming processing method, has the advantages of low production cost, high efficiency, and high processing surface integrity. The Chinese invention patent with application number 201910870567.7 discloses a flexible rolling forming method and device for metal surface microstructure arrays, which can solve the problem of large-area processing difficulties of three-dimensional complex plate surface microstructure arrays. However, this method is only suitable for large-area single blade processing under the premise of a larger space, and cannot be applied to narrow space curved thin-walled blades such as integral blade disk blades. Summary of the invention

[0004] In view of the technical problem that existing surface microstructure rolling forming methods and devices are unable to process microstructures on the surfaces of curved thin-walled blades in narrow spaces such as integral blisk blades, the present invention proposes a clamping rolling device, a curved thin-walled part surface microstructure rolling device and a method.

[0005] In order to solve the above technical problems, the technical solution of the present invention is as follows:

[0006] The clamping and rolling device is special in that it includes a connecting unit, a rolling unit, a clamp-type clamping mechanism with adjustable clamping force, and a limit connection component;

[0007] The connection unit is used to connect the clamping rolling device to the machine tool spindle of the five-axis CNC machine tool;

[0008] The rolling unit is a microstructure roller set, a smooth roller set, or a roller set consisting of a microstructure roller and a smooth roller, and is used to roll-form a micro-groove structure on the surface of the blade and / or to roll-strengthen the surface of the blade;

[0009] The clamp-type clamping mechanism is used to generate and transmit the clamping force to the rolling unit, so that the rolling unit clamps the curved thin-walled part; the middle part of the clamp-type clamping mechanism is rotatably connected to the connecting unit;

[0010] The limiting connection assembly is used to relatively mount the two rollers of the rolling unit at the front end of the clamp-type clamping mechanism, and to limit the swing range of the clamp-type clamping mechanism relative to the connection unit;

[0011] When the opening angle at the rear end of the clamp-type clamping mechanism increases, the opening angle at the front end decreases, thereby reducing the distance between the two rollers of the rolling unit to clamp the curved thin-walled part; conversely, when the opening angle at the rear end of the clamp-type clamping mechanism decreases, the opening angle at the front end increases, thereby increasing the distance between the two rollers of the rolling unit to loosen the curved thin-walled part.

[0012] Furthermore, the connecting unit includes a tool rod, which is composed of a tool shaft and a tool setting platform connected upper and lower; the upper part of the tool shaft is used to be connected to the machine tool spindle of the five-axis CNC machine tool, and the lower part of the tool shaft is used to be rotatably connected to the clamp-type clamping mechanism, and the tool setting platform is used to align the tool with the automatic tool setting instrument of the five-axis CNC machine tool.

[0013] Further, the clamp-type clamping mechanism includes a clamping force transmission mechanism and a force source component; the clamping force transmission mechanism includes a first bracket and a second bracket, and an embracing structure is provided on the inner side wall of the middle part of the first bracket and the second bracket, and both are rotatably connected to the lower part of the knife shaft through the embracing structure thereon, and the embracing structures of the two are arranged up and down;

[0014] The force source component is arranged at the rear ends of the first and second brackets, and is used to generate a controllable force to increase the opening angle at the rear ends of the first and second brackets to form the clamping force required for microstructure rolling at the front ends of the first and second brackets.

[0015] Furthermore, the force source assembly includes a spring, a connecting rod and a stopper; the spring is used to provide the controllable force, and the original length of the spring is greater than the maximum distance between the rear end of the first bracket and the rear end of the second bracket; the connecting rod is used to install the spring between the inner side wall of the rear end of the first bracket and the inner side wall of the rear end of the second bracket; the stopper is installed on the connecting rod and is located on the outside of the first bracket and the second bracket. By adjusting the position of the stopper on the connecting rod, the distance between the rear end of the first bracket and the rear end of the second bracket can be controlled to achieve adjustment of the clamping force.

[0016] Furthermore, the number of the springs, the elastic coefficient and the original length of a single spring are selected and combined according to the size and variation range of the required clamping force.

[0017] Further, the force source assembly includes a cylinder, a floating joint and a connector connected in sequence, and also includes a pneumatic device for driving the cylinder to move;

[0018] After the piston rod of the cylinder passes through the rear end of the first bracket / the second bracket, it is connected to one end of the floating joint; the other end of the floating joint is connected to one end of the connector; a hinge hole is processed on the side wall of the other end of the connector, and the end of the connector is inserted into the connecting groove on the rear end of the second bracket / the first bracket, and the end of the connector is hinged to the rear end of the second bracket / the first bracket by installing a pin in the connecting groove and the hinge hole;

[0019] The cylinder is used to provide the controllable force. By extending / retracting the piston rod of the cylinder, the distance between the rear ends of the first bracket and the second bracket can be controlled to adjust the clamping force.

[0020] Furthermore, the limiting connection assembly includes a roller cover, an end cover and a bearing; there are two roller covers, which are respectively connected to the front end of the first bracket and the front end of the second bracket, and are used to position and install the two rollers on the front end of the first bracket and the second bracket respectively; the end cover is used to limit the position of the first bracket and the second bracket to prevent them from moving vertically, and to limit the swing range of the first bracket and the second bracket; the roller cover, the first bracket and the second bracket are all installed with the bearings for supporting the rollers.

[0021] The present invention also provides a surface microstructure rolling device for curved thin-walled parts, comprising a five-axis CNC machine tool; the special feature is that it also includes the above-mentioned clamping rolling device; the clamping rolling device is installed on the main shaft of the five-axis CNC machine tool.

[0022] The present invention also provides a method for rolling a microstructure on the surface of a curved thin-walled part, which is special in that it comprises the following steps:

[0023] Step 1: Modeling and simulation of machining process;

[0024] Step 1.1 Establish a microstructure rolling device model and a blade model;

[0025] Step 1.2 compile the microstructure rolling tool path program and perform machining process simulation analysis;

[0026] Step 1.2.1 Import the blade model into the CAM software, and draw the groove trajectory curve to be processed on the surface of the blade model according to the requirements for improving aerodynamic performance;

[0027] Step 1.2.2 generates an NC file of a rolling tool path based on the groove trajectory curve to be processed;

[0028] Step 1.2.3 import the microstructure rolling device model and the blade model into the processing simulation software and assemble them;

[0029] Step 1.2.4: Perform machining process simulation analysis to obtain the NC file after safety confirmation;

[0030] Step 2: Preparation before processing;

[0031] Step 2.1 Import the safe NC file obtained in step 1.2.4 into the five-axis CNC machine tool;

[0032] Step 2.2: Clamp the curved thin-walled part to be processed onto the machine tool workbench;

[0033] Step 2.3 Fix the clamping and rolling device to the machine tool spindle and calibrate the tool with an automatic tool setting instrument;

[0034] Step 3: Execute NC file feed;

[0035] Execute the NC file, move the clamping and rolling device to a safe height above the curved thin-walled part to be processed, and rotate the machine tool spindle so that the curved thin-walled part to be processed is between the vertical projection positions of the rollers on both sides of the device, ensuring that the clamping and rolling device will not interfere with the curved thin-walled part to be processed during the feed process;

[0036] Step 4: rolling microstructure grooves on the surface of the curved thin-walled part to be processed;

[0037] The clamping rolling device descends to the starting position of the microstructure groove curve, and the front end angle of the clamping rolling device is adjusted to clamp the curved thin-walled part to be processed. The microstructure roller rolls the microstructure groove on the surface of the curved thin-walled part to be processed according to the expected trajectory under the action of the clamping force. The smooth roller provides support on the other side of the curved thin-walled part to be processed to reduce blade deformation and perform rolling strengthening until the rolling process is completed;

[0038] or,

[0039] The microstructure rollers on both sides roll-form microstructure grooves on both sides of the surface of the curved thin-walled part to be processed synchronously along the expected trajectory under the action of the clamping force until the rolling process is completed;

[0040] or,

[0041] Under the action of the clamping force, the smooth rollers on both sides synchronously roll and strengthen the surfaces of the curved thin-walled parts to be processed along the expected trajectory until the rolling process is completed.

[0042] Step 5: Adjust the roller spacing and retract the cutter;

[0043] The front end opening angle of the clamping rolling device is adjusted to increase the distance between the two rollers at the front end of the bracket so that it is larger than the thickness of the curved thin-walled part to be processed, thereby completing the tool retraction.

[0044] The beneficial effects of the present invention are as follows:

[0045] 1. The clamping rolling device of the present invention includes a rolling unit and a clamp-type clamping mechanism with adjustable clamping force. The clamp-type clamping mechanism adopts a structure in which two brackets are symmetrically distributed, thereby ensuring that the clamping forces on both sides are always equal. The microstructured rollers at the front ends of the two brackets can construct a microgroove structure on the surface of the blade, and at the same time use the smooth roller as support to reduce blade deformation and perform rolling strengthening. Through the free combination of the microstructured roller and the smooth roller, on the basis of a small amount of blade deformation, double-sided symmetrical rolling of microstructured grooves, single-sided rolling of microstructured grooves and rolling strengthening are achieved, thereby improving the aerodynamic performance and fatigue resistance of the blade, extending the service life of the blade, and reducing the production cost.

[0046] 2. The two side brackets in the clamping and rolling device of the present invention are rotatably connected to the knife rod, so that the rollers installed at the front end of the two side brackets have a certain degree of rotational freedom and can rotate with the undulation of the blade surface when the curvature of the blade profile changes; the rollers at the front end of the two side brackets clamp the blade under the action of the rear end output force, and during the rolling process, the clamping force of the front end rollers always depends on the magnitude of the rear end output force, and because the front end rollers can rotate with the undulation of the blade surface when the curvature of the blade profile changes, it is ensured that the forming depth of the micro groove is always determined by the clamping force, reducing the possibility of interference between the front end of the clamping and rolling device in the narrow flow channel space such as the integral blade disc blade; at the same time, this rotational freedom ensures the consistency of the shape and posture of the micro groove structure constructed by the rollers in the process of moving along the knife track, thereby realizing the control of the layout posture of the micro groove structure on the blade surface.

[0047] 3. The clamping and rolling device of the present invention can use a spring as a power source, and at least one spring with different parameters such as elastic coefficient and original length is used in combination at the rear end of the device. The thickness range of the blade to be processed is measured to calculate the spring deformation range, and the amplification effect of the two side brackets on the rear end spring elastic force is considered, so as to achieve control of the clamping force and the range of variation; the clamping and rolling device of the present invention can also use a cylinder as a power source. At this time, the air pressure value in the cylinder can be adjusted by a pressure reducing valve to accurately control the clamping force of the clamping and rolling device, thereby achieving active control of the clamping force and greatly improving the maximum value of the clamping force; combined with the mapping relationship between rolling force and groove forming depth in the previous test data, the effect of accurately controlling the micro-geometric morphology of the groove can be achieved.

[0048] 4. The clamping and rolling device of the present invention has a simple structure, and the calculation of the front-end clamping force is simple, which facilitates the precise control of the clamping force.

[0049] 5. The surface microstructure rolling device of the curved thin-walled part of the present invention comprises a clamp rolling device and a five-axis CNC machine tool. The clamp rolling device has a compact structure, a small volume, and a certain degree of rotational freedom at the front end. It can work in the narrow flow channel space of the integral blade disk without interference. The use state is as follows: Fig.13As shown; using a five-axis CNC machine tool to control the clamping rolling device has lower production costs and less operating difficulty than the control method of synchronous rolling by mechanical arms on both sides.

[0050] 6. The rolling method of the present invention obtains a tool trajectory by offsetting the microstructure groove curve to be processed on the blade surface according to the distance from the actual rolling contact point to the tool point of the rolling device; then the model is configured according to the actual installation method, and the generated tool trajectory is simulated and analyzed during the processing, thereby achieving rolling processing of a microgroove structure curve with high position accuracy and geometric size accuracy without interference.

[0051] 7. The clamping rolling device of the present invention can be sold separately or sold as a set together with a five-axis CNC machine tool as an integrated microstructure rolling device, which can meet the usage requirements of different scenarios.

[0052] 8. The clamping rolling device, microstructure rolling device and method of the present invention are suitable for surface microstructure processing of various curved thin-walled parts. For example, microscopic drag reduction structures and microscopic light trapping structures can be constructed on the aircraft fuselage skin, which can improve the aerodynamic performance of the aircraft fuselage to save fuel, and change the aircraft's absorption and reflectivity of electromagnetic waves to improve stealth performance; super-hydrophobic microstructures are manufactured on the surface of satellite antennas, which can greatly reduce snow adhesion and effectively improve the reception efficiency of satellite signals. Applying super-hydrophobic microstructures to the surface of aircraft wings can effectively reduce icing on the aircraft wings and improve the safety performance of the aircraft. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 It is a schematic structural diagram of Embodiment 1 of the clamping and rolling device of the present invention.

[0054] Figure 2 It is a schematic diagram of the structure of the knife bar in the first embodiment of the clamping and rolling device of the present invention.

[0055] Figure 3 It is a schematic diagram of the structure of the bracket in the first embodiment of the clamping and rolling device of the present invention.

[0056] Figure 4 Schematic diagram of the structure of the rollers in the first embodiment of the clamping and rolling device of the present invention, (a) is a microstructure roller, (b) is a smooth roller, and (c) is a side view of the microstructure roller.

[0057] Figure 5 It is a schematic diagram of the structure of the roller cover in the first embodiment of the clamping and rolling device of the present invention.

[0058] Figure 6 It is a schematic structural diagram of the end cover in the first embodiment of the clamping and rolling device of the present invention.

[0059] Figure 7It is a schematic structural diagram of the second embodiment of the clamping and rolling device in the present invention.

[0060] Figure 8 It is a schematic diagram of the structure of the cylinder bracket in the second embodiment of the clamping and rolling device of the present invention.

[0061] Fig. 9 It is a schematic diagram of the structure of the transmission bracket in the second embodiment of the clamping and rolling device of the present invention.

[0062] Fig.10 It is a schematic diagram of the structure of the cylinder in the second embodiment of the clamping and rolling device of the present invention.

[0063] Fig.11 It is a schematic diagram of the structure of the floating joint in the second embodiment of the clamping and rolling device of the present invention.

[0064] Fig.12 It is a schematic diagram of the structure of the connector in the second embodiment of the clamping and rolling device of the present invention.

[0065] Fig.13 This is a schematic diagram of the use of the clamping and rolling device of Example 2 for processing microstructure grooves on the surface of a blade in a narrow flow channel space.

[0066] Fig.14 It is a schematic structural diagram of the surface microstructure rolling device of a curved thin-walled part according to the present invention.

[0067] Fig.15 The present invention is a flow chart of the method for rolling the surface microstructure of a curved thin-walled part.

[0068] Description of reference numerals:

[0069] 100- five-axis CNC machine tool; 101- machine tool spindle; 102- machine tool working platform;

[0070] 200-clamping and rolling device; 201-tool bar; 2011-tool shaft; 2012-tool setting platform; 2013-semicircular arc surface; 2014-groove; 2015-first bolt hole; 202-first bracket; 2021-first bearing hole; 2022-first step surface; 2023-first pin hole; 2024-first bolt hole; 2025-gap groove; 2026-connecting hole; 2027-embracing structure; 203-second bracket; 204-roller; 2041-microstructure roller; 2042-smooth roller; 2043-shoulder inner ring; 2044-shoulder outer ring; 205-bearing; 206-roller Wheel cover; 2061-second bearing hole; 2062-second stepped surface; 2063-second pin hole; 2064-second bolt through hole; 207-end cover; 2071-horizontal cover plate; 2072-vertical boss; 2073-through hole; 2074-second bolt through hole; 208-spring; 209-connecting rod; 210-stopper; 211-cylinder; 212-floating joint; 213-connecting head; 214-pin shaft; 215-transmission bracket; 2151-connecting groove; 2152-slide groove; 216-cylinder bracket; 2161-connecting boss; 2162-countersunk piston rod through hole; 2163-countersunk bolt through hole;

[0071] 300-blades. DETAILED DESCRIPTION

[0072] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0073] Embodiment 1:

[0074] The present embodiment provides a clamping and rolling device 200, which can be installed on an existing five-axis CNC machine tool for use. The clamping and rolling device 200 is driven by the machine spindle of the five-axis CNC machine tool to move on the surface of the curved thin-walled blade along a set forming trajectory, forming microstructure grooves on one or both sides of the curved thin-walled blade.

[0075] like Figure 1 As shown, the clamping and rolling device 200 of this embodiment includes a connecting unit, a rolling unit, a clamp-type clamping mechanism with adjustable clamping force, and a limit connection assembly.

[0076] The connection unit is used to connect the clamping and rolling device 200 to the machine tool spindle of the five-axis CNC machine tool.

[0077] like Figure 2As shown, the connection unit includes a tool bar 201, which is composed of a tool shaft 2011 and a tool setting platform 2012 connected up and down. The tool shaft 2011 is used to connect to the machine tool spindle of the five-axis CNC machine tool, and the tool setting platform 2012 is used to set the tool with the automatic tool setting instrument of the five-axis CNC machine tool. The length of the tool shaft 2011 should ensure that when the blade root area of ​​the curved thin-walled blade is processed by the clamping rolling device 200, the machine tool spindle of the five-axis CNC machine tool will not interfere with the curved thin-walled blade. One side of the tool setting platform 2012 is a semicircular arc surface 2013 to avoid interference with the tenon root at the bottom of the blade, and the bottom surface of the other side is processed with a groove 2014, and a bolt through hole 2015 is provided in the middle of the groove 2014. The depth of the groove 2014 is greater than the thickness of the bolt head plus the spring washer when the bolt is connected, so as to ensure that the bolt head will not protrude from the bottom surface of the tool setting platform 2012, so that the accuracy during tool setting is not affected.

[0078] The rolling unit is used to roll-form micro-grooves on the surface of the blade and / or to roll-strengthen the surface of the blade. The rolling unit includes a roller 204; the roller 204 has two types, namely Figure 4 The microstructure roller 2041 shown in FIG. Figure 4 The optical roller 2042 is shown in FIG.

[0079] like Figure 4 As shown, the diameter and width of the wheel body of the microstructure roller 2031 and the light roller 2032 are equal, and the two sides of the wheel body are symmetrically provided with journals. The difference between the two is that the outer circumferential surface of the wheel body of the microstructure roller 2031 is prefabricated with a convex ridge structure that can construct a microgroove structure, and the outer circumferential surface of the light roller 2032 is a semicircular arc surface with a diameter equal to the width of the wheel body. When it is only necessary to process the microstructure on one side of the blade, the rollers 204 installed on the two brackets are respectively the microstructure roller 2041 and the light roller 2042, wherein the microstructure roller 2041 is used to roll-form the microgroove structure on the surface of the blade, and the light roller 2042 is used to provide support force at a symmetrical position on the other side of the blade, reduce the deformation of the blade and strengthen the surface of the blade; when it is necessary to process the microstructure on both sides of the blade, the rollers 204 installed on the two brackets are both the microstructure roller 2041; when it is necessary to roll-form and strengthen both sides of the blade, the rollers 204 installed on the two brackets are both the light roller 2042.

[0080] The clamp-type clamping mechanism with adjustable clamping force is used to provide an installation basis for the rolling unit, generate and transmit the clamping force to the rolling unit, so that the rolling unit clamps the curved thin-walled blade.

[0081] like Figure 1 , 3As shown, the clamp-type clamping mechanism with adjustable clamping force includes a clamping force transmission mechanism and a force source component. The clamping force transmission mechanism includes a first bracket 202 and a second bracket 203 hinged in the middle, and two rollers 204 of the rolling unit are respectively installed at the front ends of the first bracket 202 and the second bracket 203 and arranged opposite to each other. The force source component is arranged at the rear ends of the first bracket 202 and the second bracket 203, and is used to control the clamping and opening angles of the first bracket 202 and the second bracket 203, and generate an adjustable clamping force. In order to amplify the clamping force generated by the force source component, the hinge of the first bracket 202 and the second bracket 203 is closer to the rolling unit.

[0082] The front end face of the first bracket 202 is processed with a first stepped surface 2022, a first bearing hole 2021 is opened on the high plane of the first stepped surface 2022 and along the length direction of the first bracket 202, a first pin hole 2023 and two first bolt through holes 2024 are arranged on the low plane of the first stepped surface 2022, and the first pin hole 2023 is located between the two first bolt through holes 2024; a vertically penetrating spacer is arranged on the outer wall surface of the first bracket 202 at a certain distance from the first stepped surface 2022 Slot 2025, the make way slot 205 is used to provide operating space for bolt connection; the rear end of the first bracket 202 is provided with three connecting holes 2026 equidistantly along the vertical direction; further preferably, in order to prevent the bracket from being subjected to torque in other directions, the center height of the middle connecting hole 2026 is the same as the center height of the first bearing hole 2021; the upper inner part of the bracket arm of the first bracket 202 is provided with an embracing structure 2027, the inner diameter of the embracing structure 2027 is smaller than the diameter of the knife shaft 2011 so that the two can rotate relative to each other.

[0083] The structure of the second bracket 203 is similar to that of the first bracket 202, except that the embracing structure on the second bracket is located at the lower half of the inner side of the bracket arm of the second bracket, and is matched with the embracing structure 2027 on the first bracket 202. After the embracing structure 2027 of the first bracket 202 and the embracing structure of the second bracket 203 are connected up and down, the knife shaft 2011 is passed through the embracing structure of the second bracket 203 and the embracing structure 2027 of the first bracket 202 in sequence, so that the first bracket 202 and the middle part of the second bracket 203 can be hinged.

[0084] The radius of the roller 204 mounted on the first bracket 202 is equal to the distance between the center of the first bearing hole 2021 on the first bracket 202 and the bottom surface of the first bracket 202, so as to ensure that the bottom of the blade can be processed to the maximum extent during rolling. Similarly, the radius of the roller 204 mounted on the second bracket 203 is equal to the distance between the center of the first bearing hole on the second bracket 203 and the bottom surface of the second bracket 203.

[0085] The force source assembly includes a spring 208, a connecting rod 209 and a stopper 210. The spring 208 is used to provide the clamping force required for microstructure rolling. There are three connecting rods 209, which are arranged in parallel; the diameter of each connecting rod 209 is smaller than the inner diameter of the connecting hole 2026 on the rear end of the first bracket 202 and the connecting hole on the rear end of the second bracket 203 to ensure that the connecting rod and the connecting hole will not interfere when the opening angle between the first bracket and the second bracket increases within a certain angle; both ends of each connecting rod 209 are processed with external threads; the three connecting rods 209 pass through the three connecting holes on the rear ends of the first bracket 202 and the second bracket 203 respectively. There are three springs 208, which are respectively sleeved outside the three connecting rods 209 and are all located between the first bracket 202 and the second bracket 203. There are three groups of stoppers 209, two in each group, which are respectively installed at the external threads at both ends of the connecting rod 209 and threadedly matched therewith, and are used to limit the connecting rod 209 and prevent it from moving along the axis of the connecting hole 2026 on the bracket; by adjusting the spacing between the two stoppers 210 on both sides of the bracket, the opening angle of the first bracket 202 and the second bracket 203 can be controlled. The diameter of the connecting rod 209 is smaller than the inner diameter of the connecting hole 2026 on the rear end of the first bracket 202 and the second bracket 203. When the stoppers 209 are adjusted so that the opening angle of the first bracket 202 and the second bracket 203 gradually increases from zero, the angle between the connecting hole 2026 on the rear end of the first bracket 202 and the connecting hole on the rear end of the second bracket 203 also gradually decreases from parallel (180 degrees), and the gap between the connecting rod 209 and the connecting hole 2026 also becomes smaller and smaller, until the two are in contact, and the opening angle of the first bracket 202 and the second bracket 203 reaches the maximum value.

[0086] Since the function of the spring 208 is to provide a clamping force, the parameters of the spring 208 (including the number of springs, the elastic coefficient of a single spring, and the original length, etc.) can be selected and combined according to the required clamping force and the range of variation. That is to say, the number and the setting position of the spring 208 are not limited to the above-mentioned form described in this embodiment, but are diverse: for example, only one spring 208 can be set, and considering the force balance of the device, the spring should be set on the connecting rod 209 located in the middle; two springs 208 can also be set, and considering the force balance of the device, the two springs should be respectively set on the two connecting rods 209 located on the upper and lower sides. Adaptively, the number of connecting holes at the rear ends of the first bracket 202 and the second bracket 203 is not limited to three, and the number of connecting rods 209 is not limited to three, but is adaptively adjusted and designed according to the number and position of the springs 208 required to be set.

[0087] In addition, the distance between the roller 204 installed at the front end of the bracket and the knife shaft 2011 is smaller than the distance between the spring 208 located at the rear end of the bracket and the knife shaft 2011, thereby amplifying the elastic force of the rear end spring 208, and the rollers 204 on both sides of the front end exert equal forces on the profiles on both sides of the blade to reduce blade deformation.

[0088] The limiting connection assembly includes a roller cover 206, an end cover 207 and a bearing 205. There are two roller covers 206, which are respectively connected with the front end of the first bracket 202 and the front end of the second bracket 203, and are used to position and install the two rollers 204 located at the front ends of the first bracket 202 and the second bracket 203. The end cover 207 is used to limit the first bracket 202 and the second bracket 203 to prevent them from moving in the vertical direction, and to limit their swing range. There are four bearings 205, which are respectively installed on the two roller covers 206, the first bracket 202 and the second bracket 203, and are used to provide support for the rollers 204 of the rolling unit and ensure that they can rotate.

[0089] like Figure 5 As shown, taking the roller cover 206 matched with the first bracket 202 as an example, the end face of the roller cover 206 is processed with a second step surface 2062 matching the first step surface 2022 at the front end of the first bracket 202, a second bearing hole 2061 matching the first bearing hole 2021 on the first bracket 202, and a second pin hole 2063 and a second bolt hole 2064 matching the first pin hole 2023 and the first bolt hole 2024 on the first bracket 202 respectively; bearings 205 are installed in the first bearing hole 2021 and the second bearing hole 2061. After the roller cover 206 is docked with the first bracket 202, the positioning accuracy of the roller 204 and the high coaxiality of the shaft necks on both sides can be ensured by the cooperation between the second step surface 2062 and the first step surface 2022, and by installing positioning pins in the second pin hole 2063 and the first pin hole 2023; the tightness of the connection can be ensured by installing bolts in the second bolt through hole 2064 and the first bolt through hole 2024.

[0090] After assembly, the shaft necks on both sides of the wheel body of the roller 204 are transitionally matched with the inner ring of the bearing 205 on the roller cover 206 and the bearing 205 on the bracket. The bearing 205 is a deep groove ball bearing that can withstand radial force but cannot withstand large axial force; the inner rings 2043 of the shaft shoulders on both sides of the roller 204 are in contact with the end faces of the two bearings 205 to achieve the positioning of the bearing 205; the outer rings 2044 of the shaft shoulders on both sides of the roller 204 are in contact with the top surface of the first bearing hole 2021 and the top surface of the second bearing hole 2061 to limit the axial movement of the roller 204 and prevent the bearing 205 from bearing axial force; the length of the shaft necks on both sides of the roller 204 should be greater than the width of the bearing 205 and less than the depth of the first bearing hole 2021 and the second bearing hole 2061.

[0091] like Figure 6As shown, the end cover 207 includes a horizontal cover plate 2071 and a vertical boss 2072 located on one side of the horizontal cover plate 2071; the bottom surface of the horizontal cover plate 2071 contacts the top surfaces of the first bracket 202 and the second bracket 203; a through hole 2073 is provided in the middle of the horizontal end cover 2071 for the knife shaft 2011 to pass through; the bottom surface of the vertical boss 2072 contacts the top surface of the tool setting platform 2012, and the vertical boss 2072 is provided with a second bolt through hole 2074 corresponding to the first bolt through hole 2015 on one side of the tool setting platform 2012. By installing bolts in the first bolt through hole 2015 and the second bolt through hole 2074, the end cover 207 can be fixedly connected to the tool setting platform 2012. In addition, the vertical boss 2072 is at a certain distance from the side of the second bracket 203 (the present invention has no special requirements for this distance, and the main purpose is to ensure that the second bracket 203 can have a required rotation range. The larger the required rotation range, the larger the distance), so that the second bracket 203 can have space to generate a certain range of swing freedom, ensuring that the forming depth of the microstructure groove is always determined by the clamping force of the roller on the blade, and has a certain degree of adaptability to the change of the curvature of the blade surface. Since the first bracket 202 and the second bracket 203 rotate synchronously during operation, the swing freedom of the first bracket 202 is limited by the swing freedom of the second bracket 203.

[0092] The working principle and process of this embodiment are:

[0093] A spring 208 is placed between the rear end of the first bracket 202 and the rear end of the second bracket 203. The original length of the spring 208 is greater than the maximum distance between the rear ends of the device. At this time, the distance between the rear ends is always kept at the maximum value under the elastic force of the spring 208, and the front end of the device is completely clamped. The function of the stopper 210 is to control the maximum distance between the rear end of the first bracket 202 and the rear end of the second bracket 203, so as to control the minimum distance between the front end of the first bracket 202 and the front end of the second bracket 203. The distance of the adjusting block 210 increases the compressed length of the rear end spring 208. At this time, the distance at the front end of the device is greater than zero but still less than the thickness of the blade. The device is subjected to force balance under the action of the block 210, that is, the elastic force of the spring 208 on the inner side of the rear end of the first bracket 202 and the second bracket 203 is balanced with the supporting force of the block 210 on the outer side of the rear end of the first bracket 202 and the second bracket 203. At this time, the distance between the rear ends of the first bracket 202 and the second bracket 203 is adjusted to continue to decrease until the distance between the front ends of the first bracket 202 and the second bracket 203 is greater than the thickness of the blade. The blade is placed between the rollers on both sides, and the block 210 is adjusted to increase the distance between the rear end of the first bracket 202 and the rear end of the second bracket 203. Correspondingly, the distance between the front end of the first bracket 202 and the front end of the second bracket 203 will decrease until the rollers on both sides of the front end completely clamp the blade. The force analysis of the first bracket 202 and the second bracket 203 is further performed, and it is concluded that the force of the two side rollers on the blade surface at the front end is balanced with the elastic force of the spring 208 at the rear end, and the spring elastic force applied to the inner side of the first bracket 202 and the inner side of the second bracket 203 is consistent, and it is concluded that the force of the rollers on the blade surface at both sides is equal. Therefore, the increase in blade thickness will lead to an increase in the front end spacing, while the rear end spacing will decrease, and the spring 208 will be compressed, and the clamping force will increase, that is, when rolling, as the blade thickness increases (the front end spacing increases), the clamping force also increases.

[0094] Embodiment 2:

[0095] like Figure 7 As shown, the principle of this embodiment is the same as that of the first embodiment, and the structural difference is only that: the spring 207 of the clamp-type clamping mechanism with adjustable clamping force in the first embodiment is replaced by a cylinder 211, and a pneumatic device for driving the cylinder 211 is added. The cylinder 211 is used to control the clamping and opening angles of the first bracket 202 and the second bracket 203, and provide the clamping force required for microstructure rolling; after the spring 208 is replaced by the cylinder 211, it is no longer necessary to set the connecting rod 208 and the stop block 209 accordingly, and it is only necessary to make adaptive adjustments to the structures of the rear ends of the first bracket 202 and the second bracket 203 and add some accessories to realize the installation and use of the cylinder 211.

[0096] Specifically, Figure 7As shown, in this embodiment, after the force source component (spring 207, connecting rod 208 and stop block 209) in embodiment one is removed, a new force source component is added, and the new force source component includes a cylinder 211, a floating joint 212, a connecting head 213, a pin 214 and a pneumatic device. At the same time, the structure of the rear ends of the first bracket 202 and the second bracket 203 is adjusted. After the adjustment, the first bracket 202 serves as a transmission bracket 215, and the second bracket 203 serves as a cylinder bracket 216.

[0097] like Fig.10 As shown, the end surface of the cylinder 211 is provided with a plurality of through holes, and the two sides of the through holes have threads of a certain length. A piston rod extends from one end surface of the cylinder 211, and a threaded hole is provided on the end surface of the piston rod. The floating joint 212 is used to eliminate the axial offset load on the piston rod of the cylinder 211, such as Fig.11 As shown, one end of the floating joint 212 is a threaded rod, which is threadedly connected to the threaded hole on the end face of the piston rod of the cylinder 211. The other end of the floating joint 212 has a larger diameter and a threaded hole on the end face. The connector 213 is used to connect the floating joint 212 and the transmission bracket 215. Fig.12 As shown, one end of the connector 213 is an external threaded rod for threaded connection with the threaded hole of the floating joint 212 , and a hinge hole is provided on the middle side wall of the connector 213 .

[0098] like Figure 8 As shown, the front end and the middle part of the cylinder bracket 216 have the same structure as the corresponding parts of the second bracket 203 in the first embodiment, and the rear end of the cylinder bracket 216 is a connecting boss 2161 that matches the shape and size of the end face of the cylinder 211; a countersunk piston rod through hole 2162 is provided in the middle part of the connecting boss 2161 for the piston rod of the cylinder 211 to pass through, and a countersunk bolt through hole 2163 that corresponds to the threaded hole on the end face of the cylinder 211 is provided at the edge of the connecting boss 2161. The cylinder 211 can be fixedly installed on the cylinder bracket 216 by installing bolts in the threaded hole on the end face of the cylinder 211 and the countersunk bolt through hole 2163 of the connecting boss 2161.

[0099] like Fig. 9As shown, the front end and the middle part of the transmission bracket 215 are completely identical in structure to the corresponding parts of the first bracket 202 in the first embodiment, and the rear end of the transmission bracket 215 is provided with a connecting groove 2151 and a sliding groove 2152; the connecting groove 2151 is provided on the rear end surface of the transmission bracket 215 and penetrates along the width direction of the transmission bracket 215; the sliding groove 2152 is provided on the side wall of the connecting groove 2151 and penetrates; one end of the connector 213 is placed in the connecting groove 2151, the diameter of the hinge hole in the middle part of the connector 213 is equal to the width of the sliding groove 2152, and the position of the hinge hole corresponds to the sliding groove 2152; the pin shaft 214 is installed in the hinge holes in the sliding groove 2152 and the middle part of the connector 213, so that the connector 213 can be hinged to the rear end of the transmission bracket 215; the shaft end of the pin shaft 214 is fixed with a cotter pin, and the cotter pin is used to limit the axial movement of the pin shaft 214.

[0100] After assembly, the piston rod of the cylinder 211, the roller 204 and the center of the connecting groove 2151 are located in the same horizontal plane, ensuring that the torques applied to the clamping and rolling device 200 are all in the same plane.

[0101] The pneumatic device is an existing conventional unit, including an air compressor, a pneumatic triplex, a solenoid valve, a one-way throttle valve, a DC power supply and a switch. The air compressor is used to provide an air source for the cylinder 211; the pneumatic triplet includes an air filter, a pressure reducing valve and an oil mist collector; the air filter is used to filter and clean the air source and can filter out moisture in the compressed air; the pressure reducing valve is used to stabilize the air source and adjust the air source pressure to a specified pressure; the oil mist collector is used to lubricate the pneumatic components; the solenoid valve is used to control the extension, retraction and neutral stop of the piston rod of the cylinder 211 to control the clamping and opening angles of the clamping and rolling device 200; the one-way throttle valve is used to adjust the speed of the extension and retraction of the piston rod of the cylinder 211 to control the clamping and opening speed of the clamping and rolling device 200; the DC power supply is used to power the solenoid valve; the switch is used to control the power supply state of the DC power supply to the solenoid valve; the air circuit is connected in the order of the air compressor, the pneumatic triplet, the solenoid valve, the one-way throttle valve and the cylinder 211; the circuit is connected in the order of the DC power supply, the switch and the solenoid valve.

[0102] Reference Figure 7 and Fig.13 , the working principle and process of this embodiment are:

[0103] When the piston rod of the cylinder 211 is extended, the opening angle at the front end of the transmission bracket 215 and the cylinder bracket 216 decreases, and the pin shaft 214 slides backward in the slide groove 2152 until the pin shaft 214 presses against the rear wall of the slide groove 2152, at which time the clamping and rolling device 200 is just clamped; when the piston rod of the cylinder 211 is retracted, the opening angle at the front end of the clamping and rolling device 200 increases, and the pin shaft 214 slides forward in the slide groove 2152 until the pin shaft 214 reaches the front end of the slide groove 2152, at which time the opening angle at the front end of the clamping and rolling device 200 reaches the maximum value; by changing the position and length of the slide groove 2152, the maximum value of the front end spacing of the clamping and rolling device 200 can be changed to adapt to blades of different sizes.

[0104] Compared with the first embodiment, since the force source component of this embodiment uses a cylinder to generate the clamping force, the clamping force of the clamping rolling device 200 can be actively controlled more accurately and conveniently by adjusting the air pressure value in the cylinder 211 through the pressure reducing valve. At the same time, the maximum output force of the cylinder 211 is greater than the elastic force generated when the spring 208 is compressed, thereby greatly improving the maximum value of the clamping force of the device.

[0105] Embodiment three:

[0106] like Fig.14 As shown, this embodiment provides a microstructure rolling device for a curved thin-walled blade surface, comprising a five-axis CNC machine tool 100 and the clamping rolling device 200 in the first embodiment.

[0107] The five-axis CNC machine tool 100 is used to control the forming trajectory of the microstructure grooves on the blade surface, and includes a machine tool spindle 101 and a machine tool work platform 102. The machine tool spindle 101 is used to install the clamping rolling device 200. The machine tool work platform 102 is used to clamp the curved thin-walled blade to be processed.

[0108] Embodiment 4:

[0109] This embodiment provides a microstructure rolling device for a curved thin-walled blade surface, comprising a five-axis CNC machine tool 100 and the clamping rolling device 200 in the second embodiment.

[0110] The five-axis CNC machine tool 100 is used to control the forming trajectory of the microstructure grooves on the blade surface, and includes a machine tool spindle 101 and a machine tool work platform 102. The machine tool spindle 101 is used to install the clamping rolling device 200. The machine tool work platform 102 is used to clamp the curved thin-walled blade to be processed.

[0111] Embodiment five:

[0112] like Fig.15 As shown, this embodiment provides a method for rolling a blade surface with a microstructure using the curved thin-wall blade surface microstructure rolling device of embodiment 3, which specifically includes the following steps:

[0113] Step 1: Modeling and simulation of machining process;

[0114] Step 1.1 Establish a microstructure rolling device model and a blade model;

[0115] Step 1.1.1 Establish a five-axis CNC machine tool model and a clamping rolling device model;

[0116] A five-axis CNC machine tool 100 is modeled, and the main features of the five-axis CNC machine tool model include a machine tool spindle 101 and a machine tool working platform 102;

[0117] Models of various components in the clamping and rolling device 200 are established, and standard component models such as bolts, nuts and spring washers are derived at the same time. The models of various components and the standard component models are assembled to obtain the clamping and rolling device model.

[0118] Step 1.1.2 Build the blade model.

[0119] Step 1.2 compile the microstructure rolling tool path program and perform machining process simulation analysis;

[0120] Step 1.2.1 Import the blade model into the CAM software, and draw the groove trajectory curve to be processed on the surface of the blade model according to the requirements for improving aerodynamic performance;

[0121] Step 1.2.2 generates an NC file of a rolling tool path based on the groove trajectory curve to be processed;

[0122] According to the shape and position of the groove trajectory curve to be processed and the curvature change trend of the blade model surface, the appropriate tool axis vector, the advance and retreat method and the feed speed are preliminarily selected, and the tool trajectory is generated; considering that the tool position point of the clamp rolling device 200 is the projection point of the axis of the tool axis 2011 on the bottom surface of the tool setting platform 2012, the generated tool trajectory is offset according to the distance from the contact point between the microstructure roller 2041 and the blade model to the tool position point, so as to obtain a rolling tool path suitable for the clamp rolling device 200, and the rolling tool path is post-processed for the control system used by the five-axis CNC machine tool 100 to obtain an NC file (CNC program file);

[0123] Step 1.2.3 import the microstructure rolling device model and the blade model into the processing simulation software and assemble them;

[0124] Configure the five-axis CNC machine tool model and its control system, define the five-axis CNC machine tool model according to the coordinate axes and spindle components, import the clamping and rolling device model as the tool model, and import the blade model as the workpiece model; fix the clamping and rolling device model to the machine tool spindle model according to the installation method of the actual processing process, and clamp the blade model to the machine tool workbench model;

[0125] Step 1.2.4: Conduct machining process simulation analysis;

[0126] Import the NC file to simulate the machining process and observe whether the microstructure rolling device model will interfere or collide with the blade model during the simulation process; if interference or collision occurs, optimize the tool axis vector, advance and retreat method, etc. of the microstructure rolling model until no problem occurs, ensuring the program security of this NC file. Finally, export the confirmed safe NC file for actual rolling processing.

[0127] Step 2: Preparation before processing;

[0128] Step 2.1: import the safe NC file obtained in step 1.2.4 into the five-axis CNC machine tool 100;

[0129] Step 2.2: Clamp the blade 300 onto the machine tool workbench 102;

[0130] Step 2.3 Preparation of the clamping and rolling device;

[0131] Step 2.3.1 Install the roller 204 according to processing requirements;

[0132] According to the specific position of the microstructure groove to be processed, a microstructure roller 2041 is installed on the corresponding side of the clamping rolling device 200, and a smooth roller 2042 is installed on the other side; if the microstructure groove is to be constructed symmetrically on both sides of the blade 300, the microstructure roller 2041 is installed on both sides;

[0133] The two side journals of the roller 204 are interference fit with the two bearings 205, and the end faces of the bearings 205 are in surface contact with the inner ring of the roller 204 shoulder; the outer ring of the bearing 205 on one side is clearance fit with the first bearing hole 2021 of the first bracket 202, and the outer ring of the bearing 205 on the other side is clearance fit with the second bearing hole 2061 of the roller cover 206; the first step surface 2022 and the second step surface 2062 are aligned; the pin connection adopts interference fit, and the first pin hole 2023 is Place a locating pin in the second pin hole 2063; fasten the bracket and the roller cover 206, the first step surface 2022 and the second step surface 2062 are in surface contact, and the outer rings of the shoulders on both sides of the roller 204 are in contact with the top surfaces of the first bearing hole 2021 and the second bearing hole 2061 respectively; place bolts in the two pairs of first bolt through holes 2024 and second bolt through holes 2064, place spring washers through the clearance grooves 2025 and tighten the nuts to ensure the tightness of the roller 204 installation.

[0134] Repeat the above steps to install the roller 204 on the other side.

[0135] Step 2.3.2 Install the bracket, end cover and knife bar;

[0136] First, the second bracket 203 is connected to the knife bar 201 through the knife shaft 2011, and the bottom surface of the second bracket 203 contacts the top surface of the knife setting platform 2012, and then the first bracket 202 is installed to the knife bar 201 in the same way;

[0137] The end cover 207 is connected to the tool rod 201 through the through hole 2073 with a clearance fit with the tool shaft 2011. The vertical boss 2072 is located on the side of the second bracket 203. The bottom surface of the horizontal cover plate 2071 of the end cover 207 is in contact with the top surfaces of the first bracket 202 and the second bracket 203, and the bottom surface of the vertical boss 2072 is in contact with the top surface of the tool setting platform 2012; the bolt is placed in the second bolt through hole 2074 on the vertical boss 2062 and the first bolt through hole 2015 on the tool setting platform 2012, a spring washer is placed on the bolt at the groove 2014 on one side of the bottom surface of the tool setting platform 2012 and the nut is tightened, and the axial movement of the first bracket 202 and the second bracket 203 along the tool shaft 2011 is limited by the bolt connection.

[0138] Step 2.3.3 Install the spring according to processing requirements;

[0139] According to the mapping relationship between the working load and the micro groove depth in the previous test data, the deformation range of the spring 208 is calculated by measuring the thickness range of the blade 300, and the amplification multiple of the elastic force of the spring 208 by the clamping and rolling device 200 is considered, and the spring 208 with the appropriate number, elastic coefficient and original length is selected and installed;

[0140] Install the spring 208 between the two corresponding connecting holes on the first bracket 202 and the second bracket 203, pass the connecting rod 209 through the spring 208 and the corresponding connecting holes on the rear ends of the first bracket and the second bracket at the same time, and then install two stoppers 210 at both ends of the connecting rod 209 through threaded connections, and the stoppers 210 are in contact with the outer side surfaces of the two brackets.

[0141] The distance between the two stoppers 209 is adjusted to be smaller, so as to increase the distance between the two rollers 204 at the front end of the bracket to be greater than the thickness of the blade 300;

[0142] Step 2.4: Fix the clamping and rolling device 200 to the machine tool spindle 101, and calibrate the tool using an automatic tool setting instrument;

[0143] Step 3: Execute NC file feed;

[0144] Execute the NC file, move the clamping and rolling device 200 to a safe height above the blade 300, and rotate the machine tool spindle 101 so that the blade 300 is between the vertical projection positions of the rollers 204 on both sides of the device, to ensure that the clamping and rolling device 200 will not interfere with the blade 300 during the feeding process;

[0145] Step 4: rolling microstructure grooves on the blade surface;

[0146] The clamping and rolling device 200 descends to the starting position of the microstructure groove curve, and the spacing of the block 209 is adjusted so that the clamping and rolling device 200 clamps the blade 300. The microstructure roller 2041 rolls the microstructure groove on the surface of the blade 300 along the expected trajectory under the action of the clamping force. The smooth roller 2042 provides support on the other side of the blade 300 to reduce blade deformation and perform rolling reinforcement until the rolling process is completed.

[0147] Step 5: Adjust the roller spacing and retract the cutter;

[0148] The distance between the two stoppers 209 is adjusted to increase the distance between the two rollers 204 at the front end of the bracket to be larger than the thickness of the blade 300, thereby completing the blade retraction.

[0149] Embodiment six:

[0150] like Fig.15 As shown, this embodiment provides a method for rolling a blade surface with a microstructure using the curved thin-wall blade surface microstructure rolling device of the fourth embodiment, which specifically includes the following steps:

[0151] Step 1: Modeling and simulation of machining process;

[0152] Step 1.1 Establish a microstructure rolling device model and a blade model;

[0153] Step 1.1.1 Establish a five-axis CNC machine tool model and a clamping rolling device model;

[0154] A five-axis CNC machine tool 100 is modeled, and the main features of the five-axis CNC machine tool model include a machine tool spindle 101 and a machine tool working platform 102;

[0155] Models of various components in the clamping and rolling device 200 are established, and standard component models such as bolts, nuts and spring washers are derived at the same time. The models of various components and the standard component models are assembled to obtain the clamping and rolling device model.

[0156] Step 1.1.2 Build the blade model.

[0157] Step 1.2 compile the microstructure rolling tool path program and perform machining process simulation analysis;

[0158] Step 1.2.1 Import the blade model into the CAM software, and draw the groove trajectory curve to be processed on the surface of the blade model according to the requirements for improving aerodynamic performance;

[0159] Step 1.2.2 generates an NC file based on the groove trajectory curve to be processed;

[0160] According to the shape and position of the groove trajectory curve to be processed and the curvature change trend of the blade model surface, the appropriate tool axis vector, the advance and retreat method and the feed speed are preliminarily selected, and the tool trajectory is generated; considering that the tool position point of the clamp rolling device 200 is the projection point of the axis of the tool axis 2011 on the bottom surface of the tool setting platform 2012, the generated tool trajectory is offset according to the distance from the contact point between the microstructure roller 2041 and the blade model to the tool position point, so as to obtain a rolling tool path suitable for the clamp rolling device 200, and the rolling tool path is post-processed for the control system used by the five-axis CNC machine tool 100 to obtain an NC file (CNC program file);

[0161] Step 1.2.3: Import the microstructure rolling device model and the blade model into the processing simulation software and assemble them;

[0162] Configure the five-axis CNC machine tool model and its control system, define the five-axis CNC machine tool model according to the coordinate axes and spindle components, import the clamping and rolling device model as the tool model, and import the blade model as the workpiece model; fix the clamping and rolling device model to the machine tool spindle model according to the installation method of the actual processing process, and clamp the blade model to the machine tool workbench model;

[0163] Step 1.2.4: Conduct machining process simulation analysis;

[0164] Import the NC file to simulate the machining process and observe whether the microstructure rolling device model will interfere or collide with the blade model during the simulation process; if interference or collision occurs, optimize the tool axis vector, advance and retreat method, etc. of the microstructure rolling model until no problem occurs, ensuring the program security of this NC file. Finally, export the confirmed safe NC file for actual rolling processing.

[0165] Step 2: Preparation before processing;

[0166] Step 2.1: import the safe NC file obtained in step 1.2.4 into the five-axis CNC machine tool 100;

[0167] Step 2.2: Clamp the blade 300 onto the machine tool workbench 102;

[0168] Step 2.3: Preparation of the clamping and rolling device;

[0169] Step 2.3.1 Install the roller 204 according to processing requirements;

[0170] According to the specific position of the microstructure groove to be processed, a microstructure roller 2041 is installed on the corresponding side of the clamping rolling device 200, and a smooth roller 2042 is installed on the other side; if the microstructure groove is to be constructed symmetrically on both sides of the blade 300, the microstructure roller 2041 is installed on both sides;

[0171] The two side journals of the roller 204 are interference fit with the two bearings 205, and the end faces of the bearings 205 are in surface contact with the inner ring of the roller 204 shoulder; the outer ring of the bearing 205 on one side is clearance fit with the first bearing hole 2021 of the first bracket 202, and the outer ring of the bearing 205 on the other side is clearance fit with the second bearing hole 2061 of the roller cover 206; the first step surface 2022 and the second step surface 2062 are aligned; the pin connection adopts interference fit, and the first pin hole 2023 is Place a locating pin in the second pin hole 2063; fasten the bracket and the roller cover 206, the first step surface 2022 and the second step surface 2062 are in surface contact, and the outer rings of the shoulders on both sides of the roller 204 are in contact with the top surfaces of the first bearing hole 2021 and the second bearing hole 2061 respectively; place bolts in the two pairs of first bolt through holes 2024 and second bolt through holes 2064, place spring washers through the clearance grooves 2025 and tighten the nuts to ensure the tightness of the roller 204 installation.

[0172] Repeat the above steps to install the roller 204 on the other side.

[0173] Step 2.3.2 Install the cylinder and its related parts;

[0174] Pass the piston rod of the cylinder 211 through the countersunk piston rod through hole 2162 on the connecting boss 2161 at the rear end of the cylinder bracket 216, and threadedly connect it to one end of the floating joint 212; then align the threaded hole on the end face of the cylinder 211 with the countersunk bolt through hole 2163 on the end face of the connecting boss 2161, and ensure that the end face of the cylinder 211 is in contact with the outer end face of the connecting boss 2161, and screw the bolt into the threaded hole on the end face of the cylinder 211 through the countersunk bolt through hole 2163 on the connecting boss 2161 to fix the cylinder 211 to the cylinder bracket 216;

[0175] Screw the threaded rod at one end of the connector 213 into the threaded hole of the floating joint 212, and place the other end of the connector 213 in the connecting groove 2151 at the rear end of the transmission bracket 215, making surface contact with the two side surfaces of the connecting groove 2151, aligning the hinge hole of the connector 213 with the slide groove 2152 on the side wall of the connecting groove 2151, and passing the pin 214 through the slide groove 2152 and the hinge hole of the connector 213, and fitting with the clearance between the two, and fixing the shaft end with a cotter pin;

[0176] Step 2.3.4: Connect the pneumatic device to the clamping and rolling device and adjust it;

[0177] Connect the air circuit in the order of air compressor, pneumatic triplet, solenoid valve, one-way throttle valve, and cylinder; connect the circuit in the order of DC power supply, switch, and solenoid valve. Turn on the air compressor to supply air to the air circuit, and adjust the pressure reducing valve of the pneumatic triplet to make the air pressure in the cylinder 211 reach the target value based on the mapping relationship between the working load and the depth of the micro groove in the previous test data, combined with the output force curve of the cylinder 211 with respect to the air pressure, and considering the amplification multiple of the output force of the clamping and rolling device 200 on the cylinder 211; then use the one-way throttle valve to adjust the speed of the cylinder extending or retracting to control the clamping and opening speed of the clamping and rolling device 200 to meet the requirements;

[0178] The piston rod of the cylinder 211 is retracted by controlling the electromagnetic valve through the switch, so as to increase the distance between the rollers 204 on both sides of the front end of the clamping rolling device 200 so that it is greater than the thickness of the blade 310 .

[0179] Step 4: rolling microstructure grooves on the blade surface;

[0180] The clamping and rolling device 200 descends to the starting position of the microstructure groove curve, and the piston rod of the cylinder 211 is extended by controlling the solenoid valve through the switch. The clamping and rolling device 200 clamps the blade 300, and the microstructure roller 2041 rolls the microstructure groove on the surface of the blade 300 according to the expected trajectory under the action of the clamping force. The smooth roller 2042 provides support on the other side of the blade 300 to reduce blade deformation, and performs rolling reinforcement until the rolling process is completed.

[0181] Step 5: Adjust the roller spacing and retract the cutter;

[0182] The piston rod of the cylinder 211 is retracted by controlling the electromagnetic valve through the switch, so as to increase the distance between the rollers 204 on both sides of the front end of the clamping rolling device to be greater than the thickness of the blade 300, thereby completing the blade retraction.

[0183] The above embodiments are only described by taking the processing of thin-walled curved blades as an example. It should be pointed out that the present invention is not only applicable to the processing of thin-walled curved blades, but also applicable to the processing of other curved thin-wall parts.

Claims

1. The clamping and rolling device is characterized by: It includes a connecting unit, a rolling unit, a clamp-type clamping mechanism with adjustable clamping force, and a limit connecting component; The connection unit is used to connect the clamping rolling device to the machine tool spindle of the five-axis CNC machine tool; The rolling unit is a microstructure roller set, a smooth roller set, or a roller set consisting of a microstructure roller and a smooth roller, and is used to roll-form a micro-groove structure on the surface of the blade and / or to roll-strengthen the surface of the blade; The clamp-type clamping mechanism is used to generate and transmit the clamping force to the rolling unit, so that the rolling unit clamps the curved thin-walled part; the middle part of the clamp-type clamping mechanism is rotatably connected to the connecting unit; The limiting connection assembly is used to relatively mount the two rollers of the rolling unit at the front end of the clamp-type clamping mechanism, and to limit the swing range of the clamp-type clamping mechanism relative to the connection unit; When the opening angle at the rear end of the clamp-type clamping mechanism increases, the opening angle at the front end decreases, thereby reducing the distance between the two rollers of the rolling unit to clamp the curved thin-walled part; conversely, when the opening angle at the rear end of the clamp-type clamping mechanism decreases, the opening angle at the front end increases, thereby increasing the distance between the two rollers of the rolling unit to loosen the curved thin-walled part.

2. The clamping and rolling device according to claim 1 is characterized in that: The connecting unit includes a tool rod, which is composed of a tool shaft and a tool setting platform connected upper and lower; the upper part of the tool shaft is used to be connected to the machine tool spindle of the five-axis CNC machine tool, the lower part of the tool shaft is used to be rotatably connected to the clamp-type clamping mechanism, and the tool setting platform is used to align the tool with the automatic tool setting instrument of the five-axis CNC machine tool.

3. The clamping and rolling device according to claim 2 is characterized in that: The clamp-type clamping mechanism includes a clamping force transmission mechanism and a force source component; the clamping force transmission mechanism includes a first bracket and a second bracket, and an embracing structure is provided on the inner side wall of the middle part of the first bracket and the second bracket, and both are rotatably connected with the lower part of the knife shaft through the embracing structure thereon, and the embracing structures of the two are arranged up and down; The force source component is arranged at the rear ends of the first and second brackets, and is used to generate a controllable force to increase the opening angle at the rear ends of the first and second brackets to form the clamping force required for microstructure rolling at the front ends of the first and second brackets.

4. The clamping and rolling device according to claim 3 is characterized in that: The force source assembly includes a spring, a connecting rod and a stopper; the spring is used to provide the controllable force, and the original length of the spring is greater than the maximum distance between the rear end of the first bracket and the rear end of the second bracket; the connecting rod is used to install the spring between the inner side wall of the rear end of the first bracket and the inner side wall of the rear end of the second bracket; the stopper is installed on the connecting rod and is located on the outside of the first bracket and the second bracket. By adjusting the position of the stopper on the connecting rod, the distance between the rear end of the first bracket and the rear end of the second bracket can be controlled to achieve adjustment of the clamping force.

5. The clamping and rolling device according to claim 4 is characterized in that: The number of the springs, the elastic coefficient and the original length of a single spring are selected and combined according to the size and variation range of the required clamping force.

6. The clamping and rolling device according to claim 3 is characterized in that: The force source assembly includes a cylinder, a floating joint and a connector connected in sequence, and also includes a pneumatic device for driving the cylinder to move; After the piston rod of the cylinder passes through the rear end of the first bracket / the second bracket, it is connected to one end of the floating joint; the other end of the floating joint is connected to one end of the connector; a hinge hole is processed on the side wall of the other end of the connector, and the end of the connector is inserted into the connecting groove on the rear end of the second bracket / the first bracket, and the end of the connector is hinged to the rear end of the second bracket / the first bracket by installing a pin in the connecting groove and the hinge hole; The cylinder is used to provide the controllable force. By extending / retracting the piston rod of the cylinder, the distance between the rear ends of the first bracket and the second bracket can be controlled to adjust the clamping force.

7. The clamping and rolling device according to any one of claims 2 to 6, characterized in that: The limiting connection assembly includes a roller cover, an end cover and a bearing; there are two roller covers, which are respectively connected to the front end of the first bracket and the front end of the second bracket, and are used to position and install the two rollers on the front end of the first bracket and the second bracket respectively; the end cover is used to limit the position of the first bracket and the second bracket to prevent them from moving vertically, and to limit the swing range of the first bracket and the second bracket; the roller cover, the first bracket and the second bracket are all installed with the bearings for supporting the rollers.

8. A microstructure rolling device for a curved thin-walled part surface, comprising a five-axis CNC machine tool; characterized in that: It also includes the clamping and rolling device described in any one of claims 1-7; the clamping and rolling device is installed on the main shaft of the five-axis CNC machine tool.

9. A method for rolling a microstructure on a curved thin-walled part, characterized in that: The following steps are involved: Step 1: Modeling and simulation of machining process; Step 1.1 Establish a microstructure rolling device model and a blade model; Step 1.2 compile the microstructure rolling tool path program and perform machining process simulation analysis; Step 1.2.1 Import the blade model into the CAM software, and draw the groove trajectory curve to be processed on the surface of the blade model according to the requirements for improving aerodynamic performance; Step 1.2.2 generates an NC file of a rolling tool path based on the groove trajectory curve to be processed; Step 1.2.3 import the microstructure rolling device model and the blade model into the processing simulation software and assemble them; Step 1.2.4: Perform machining process simulation analysis to obtain the NC file after safety confirmation; Step 2: Preparation before processing; Step 2.1 Import the safe NC file obtained in step 1.2.4 into the five-axis CNC machine tool; Step 2.2: Clamp the curved thin-walled part to be processed onto the machine tool workbench; Step 2.3 Fix the clamping and rolling device to the machine tool spindle and calibrate the tool with an automatic tool setting instrument; Step 3: Execute NC file feed; Execute the NC file, move the clamping and rolling device to a safe height above the curved thin-walled part to be processed, and rotate the machine tool spindle so that the curved thin-walled part to be processed is between the vertical projection positions of the rollers on both sides of the device, ensuring that the clamping and rolling device will not interfere with the curved thin-walled part to be processed during the feed process; Step 4: rolling microstructure grooves on the surface of the curved thin-walled part to be processed; The clamping rolling device descends to the starting position of the microstructure groove curve, and the front end angle of the clamping rolling device is adjusted to clamp the curved thin-walled part to be processed. The microstructure roller rolls the microstructure groove on the surface of the curved thin-walled part to be processed according to the expected trajectory under the action of the clamping force. The smooth roller provides support on the other side of the curved thin-walled part to be processed to reduce blade deformation and perform rolling strengthening until the rolling process is completed; or, The microstructure rollers on both sides roll-form microstructure grooves on both sides of the surface of the curved thin-walled part to be processed synchronously along the expected trajectory under the action of the clamping force until the rolling process is completed; or, Under the action of the clamping force, the smooth rollers on both sides synchronously roll and strengthen the surfaces of the curved thin-walled parts to be processed along the expected trajectory until the rolling process is completed. Step 5: Adjust the roller spacing and retract the cutter; The front end opening angle of the clamping rolling device is adjusted to increase the distance between the two rollers at the front end of the bracket so that it is larger than the thickness of the curved thin-walled part to be processed, thereby completing the tool retraction.

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