Clamping and rolling device, and method for rolling surface microstructure of curved thin-walled part

Abstract

In view to the technical problem that the existing surface microstructure roll forming method and device cannot process microstructure on the surface of the narrow space curved surface thin wall blade such as the blade of the integral blade disc, the application provides a clamping roll forming device, a curved surface thin wall part surface microstructure roll forming device and method.The clamping roll forming device comprises a roll forming unit and a pincer clamping mechanism with adjustable clamping force, the pincer clamping mechanism adopts a structure with two supports symmetrically distributed, so that the clamping forces on both sides are always equal, the microstructure roller at the front end of the two supports can construct microgroove structure on the surface of the blade, the smooth roller is used as support to reduce the deformation of the blade, and roll forming strengthening is carried out; through the free combination of the microstructure roller and the smooth roller, on the basis that the deformation of the blade is small, double-sided symmetric roll forming microstructure groove, single-sided roll forming microstructure groove and roll forming strengthening are realized, the aerodynamic performance and the fatigue resistance of the blade are improved, the service life of the blade is prolonged, and the production cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of metal surface microstructure processing technology. Background Technology

[0002] Currently, aero-engine compressors are developing towards lighter weight, greater compactness, higher load capacity, and higher aerodynamic efficiency. Research has found that the introduction of meso-microstructures such as grooves in multi-scale functional surface blades can significantly reduce blade drag, but this also presents new challenges to controlling fatigue resistance during manufacturing.

[0003] Existing traditional methods for processing surface microstructures include grinding, ultra-precision machining, and femtosecond laser technology. Grinding is limited by the narrow flow channel space of the impeller, ultra-precision machining has low processing efficiency, and femtosecond laser processing struggles to achieve the required compressive stress state. Surface microstructure roll forming technology, as a novel method for plastic forming of surface microstructures, offers advantages such as low production cost, high efficiency, and high surface integrity. Chinese invention patent application number 201910870567.7 discloses a flexible roll forming method and apparatus for metal surface microstructure arrays, which can solve the problem of large-area processing difficulties for microstructure arrays on three-dimensional complex plates. However, this method is only suitable for processing large-area single blades in relatively large spaces and cannot be applied to narrow-space curved thin-walled blades such as integral impeller blades. Summary of the Invention

[0004] To address the technical problem that existing surface microstructure rolling forming methods and devices cannot process microstructures on the surface of curved thin-walled blades in narrow spaces such as integral bladed disks, this invention proposes a clamping rolling device, a surface microstructure rolling device and method for curved thin-walled parts.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0006] The special feature of the clamping and rolling device is that it includes a connecting unit, a rolling unit, a clamping mechanism with adjustable clamping force, and a limiting connection assembly.

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

[0008] The rolling unit is a microstructure roller group, a smooth roller group, or a roller group composed of microstructure rollers and smooth rollers, used to roll and form microgroove structures on the blade surface, and / or to roll and strengthen the blade surface;

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

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

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

[0012] Furthermore, the connecting unit includes a tool holder, which is composed of a tool shaft and a tool setting platform connected vertically; the upper part of the tool shaft is used to connect to the machine tool spindle of the five-axis CNC machine tool, the lower part of the tool shaft is used to rotatably connect to the clamping mechanism, and the tool setting platform is used to set the tool with the automatic tool setter of the five-axis CNC machine tool.

[0013] Furthermore, the clamping mechanism includes a clamping force transmission mechanism and a force source assembly; the clamping force transmission mechanism includes a first bracket and a second bracket, both of which have a ring-shaped structure on their inner sidewalls in the middle, and both are rotatably connected to the lower part of the cutter shaft through the ring-shaped structure thereon, and the ring-shaped structures of the two are arranged vertically.

[0014] The force source component is located at the rear end of the first and second supports to generate a controllable force, which increases the angle between the rear ends of the first and second supports to form the clamping force required for microstructure rolling at the front ends of the first and second supports.

[0015] Furthermore, the force source assembly includes a spring, a connecting rod, and a stop; 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 ends of the first support and the rear ends of the second support; the connecting rod is used to install the spring between the inner sidewalls of the rear ends of the first support and the second support; the stop is installed on the connecting rod and located outside the first and second supports. By adjusting the position of the stop on the connecting rod, the distance between the rear ends of the first support and the rear ends of the second support can be controlled, thereby adjusting the clamping force.

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

[0017] Furthermore, the power 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 / 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 machined on the side wall of the other end of the connector, and this end of the connector is inserted into the connecting groove on the rear end of the second bracket / first bracket. By inserting a pin into the connecting groove and the hinge hole, the end of the connector is hinged to the rear end of the second bracket / first bracket.

[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, thereby adjusting 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 respectively cooperate with the front end of the first bracket and the front end of the second bracket 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, prevent them from moving vertically, and limit the swing range of the first bracket and the second bracket; the bearing is installed on the roller cover, the first bracket and the second bracket to support the rollers.

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

[0022] This invention also provides a method for rolling microstructures on the surface of curved thin-walled parts, characterized by the following steps:

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

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

[0025] Step 1.2: Compile the microstructure rolling toolpath program and perform simulation analysis of the machining process;

[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 aerodynamic performance improvement requirements;

[0027] Step 1.2.2 Generate the NC file of the rolling toolpath based on the groove trajectory curve to be processed;

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

[0029] Step 1.2.4 Perform a simulation analysis of the machining process to obtain the NC file after confirming safety;

[0030] Step 2: Preparations before processing;

[0031] Step 2.1 Import the confirmed 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 worktable;

[0033] Step 2.3 Fix the clamping and rolling device onto the machine tool spindle and use an automatic tool setter to set the tool;

[0034] Step 3: Execute the NC file for tool 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, so as to ensure 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: Roll microstructure grooves onto the surface of the curved thin-walled part to be processed;

[0037] The clamping and rolling device is lowered to the starting position of the microstructure groove curve. The front angle of the clamping and rolling device is adjusted to clamp the curved thin-walled part to be processed. Under the action of clamping force, the microstructure roller rolls the microstructure groove on the surface of the curved thin-walled part to be processed along the expected trajectory. 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 reinforcement until the rolling process is completed.

[0038] or,

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

[0040] or,

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

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

[0043] Adjust the front angle of the clamping and rolling device to increase the distance between the two rollers at the front of the support so that it is greater than the thickness of the curved thin-walled part to be processed, and complete the tool retraction.

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

[0045] 1. The clamping and rolling device of the present invention includes a rolling unit and a clamping mechanism with adjustable clamping force. The clamping mechanism adopts a structure with two symmetrically distributed supports to ensure that the clamping force on both sides is always equal. The microstructure rollers at the front end of the two supports can construct microgroove structures on the blade surface, while the smooth rollers are used as supports to reduce blade deformation and perform rolling strengthening. Through the free combination of microstructure rollers and smooth rollers, double-sided symmetrical rolling of microstructure grooves, single-sided rolling of microstructure grooves and rolling strengthening are achieved with small blade deformation, thereby improving the aerodynamic performance and fatigue resistance of the blade, extending the blade service life and reducing production costs.

[0046] 2. In the clamping rolling device of the present invention, the two side supports are rotatably connected to the cutter bar, so that the rollers installed at the front end of the two side supports 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 supports clamp the blade under the action of the output force at the rear end. During the rolling process, the clamping force of the front rollers always depends on the magnitude of the output force at the rear end. And because the front 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 microgroove is always determined by the clamping force, reducing the possibility of interference at the front end of the clamping rolling device in the narrow flow channel space such as the blade of the integral bladed disk. At the same time, this degree of rotational freedom ensures the consistency of the shape and posture of the microgroove structure constructed by the rollers during the movement along the cutter rail, realizing the control of the arrangement posture of the microgroove structure on the blade surface.

[0047] 3. The clamping and rolling device of the present invention can use a spring as a power source. At least one spring with different parameters such as elastic coefficient and original length can be used at the rear end of the device. The spring deformation range is calculated by measuring the thickness range of the blade to be processed. At the same time, the amplification effect of the two side supports on the spring force of the rear end is considered, so as to achieve control over the magnitude and range of clamping force. The clamping and rolling device of the present invention can also use a cylinder as a power source. In this case, the air pressure value in the cylinder can be adjusted by a pressure reducing valve to precisely control the clamping force of the clamping and rolling device, realize active control of the clamping force, and greatly improve 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 precisely controlling the micro-geometry of the groove can be achieved.

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

[0049] 5. The surface microstructure rolling device for curved thin-walled parts of the present invention includes a clamping rolling device and a five-axis CNC machine tool. The clamping rolling device has a compact structure, small size, and a certain degree of rotational freedom at the front end. It can work in the narrow flow channel space of the integral bladed disk without interference. Its usage state is as follows: Figure 13As shown, using a five-axis CNC machine tool to control the clamping and rolling device results in lower production costs and less operational difficulty compared to the control method of synchronous rolling by two robotic arms.

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

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

[0052] 8. The clamping rolling device, microstructure rolling device and method of the present invention are applicable to the microstructure processing of various curved thin-walled parts. For example, they can also be used to construct micro-drag reduction structures and micro-light trapping structures on aircraft fuselage skin, which can improve the aerodynamic performance of the aircraft fuselage to save fuel and change the absorption and reflection rate of electromagnetic waves to improve stealth performance. The fabrication of superhydrophobic microstructures on the surface of satellite antennas can greatly reduce snow adhesion and effectively improve the reception efficiency of satellite signals. Applying superhydrophobic microstructures to the surface of aircraft wings can effectively reduce icing on aircraft wings and improve the safety performance of aircraft. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of the structure of the clamping and rolling device according to Embodiment 1 of the present invention.

[0054] Figure 2 This is a schematic diagram of the tool bar structure in Embodiment 1 of the clamping and rolling device of the present invention.

[0055] Figure 3 This is a schematic diagram of the support structure in Embodiment 1 of the clamping and rolling device of the present invention.

[0056] Figure 4 This is a schematic diagram of the roller structure in Embodiment 1 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 This is a schematic diagram of the roller cover in Embodiment 1 of the clamping and rolling device of the present invention.

[0058] Figure 6 This is a schematic diagram of the end cap structure in Embodiment 1 of the clamping and rolling device of the present invention.

[0059] Figure 7This is a schematic diagram of the structure of Embodiment 2 of the clamping and rolling device in this invention.

[0060] Figure 8 This is a schematic diagram of the cylinder support structure in Embodiment 2 of the clamping and rolling device of the present invention.

[0061] Figure 9 This is a schematic diagram of the transmission bracket in Embodiment 2 of the clamping and rolling device of the present invention.

[0062] Figure 10 This is a schematic diagram of the cylinder structure in Embodiment 2 of the clamping and rolling device of the present invention.

[0063] Figure 11 This is a schematic diagram of the floating joint in Embodiment 2 of the clamping and rolling device of the present invention.

[0064] Figure 12 This is a schematic diagram of the connector structure in Embodiment 2 of the clamping and rolling device of the present invention.

[0065] Figure 13 This is a schematic diagram of the usage state of the clamping and rolling device in Example 2 for machining microstructured grooves on the surface of blades in a narrow flow channel space.

[0066] Figure 14 This is a schematic diagram of the surface microstructure rolling device for curved thin-walled parts according to the present invention.

[0067] Figure 15 This is a flowchart of the surface microstructure rolling method for curved thin-walled parts according to the present invention.

[0068] Explanation of reference numerals in the attached figures:

[0069] 100 - Five-axis CNC machine tool; 101 - Machine tool spindle; 102 - Machine tool work platform;

[0070] 200-Clamping and rolling device; 201-Tool holder; 2011-Tool shaft; 2012-Tool setting platform; 2013-Semi-circular arc surface; 2014-Groove; 2015-First bolt through hole; 202-First bracket; 2021-First bearing hole; 2022-First stepped surface; 2023-First pin hole; 2024-First bolt through hole; 2025-Relief groove; 2026-Connecting hole; 2027-Encircling structure; 203-Second bracket; 204-Roller; 2041-Microstructure roller; 2042-Smooth roller; 2043-Inner ring of shaft shoulder; 2044 - Shoulder outer ring; 205- Bearing; 206- Roller 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- Stop block; 211- Cylinder; 212- Floating joint; 213- Connecting head; 214- Pin; 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-blade. Detailed Implementation

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

[0073] Example 1:

[0074] This embodiment provides a clamping rolling device 200, which can be installed on an existing five-axis CNC machine tool. The machine tool spindle drives the clamping rolling device 200 to move on the surface of the curved thin-walled blade along a set forming trajectory, forming micro-structured 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 clamping mechanism with adjustable clamping force, and a limiting connecting component.

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

[0077] like Figure 2As shown, the connecting unit includes a tool holder 201, which consists of a tool shaft 2011 and a tool setting platform 2012 connected vertically. The tool shaft 2011 is used to connect to the spindle of a five-axis CNC machine tool, and the tool setting platform 2012 is used to set the tool with the automatic tool setter of the five-axis CNC machine tool. The length of the tool shaft 2011 should ensure that the spindle of the five-axis CNC machine tool will not interfere with the curved thin-walled blade when machining the root region of the blade using the clamping and rolling device 200. One side of the tool setting platform 2012 is a semi-circular arc surface 2013 to avoid interference with the tenon root at the bottom of the blade. The bottom surface of the other side is machined 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 bolting, ensuring that the bolt head does not protrude from the bottom surface of the tool setting platform 2012, so that the accuracy is not affected during tool setting.

[0078] The rolling unit is used to roll-form microgroove structures on the blade surface and / or to roll-strengthen the blade surface. The rolling unit includes rollers 204; there are two types of rollers 204, namely... Figure 4 The microstructure roller 2041 shown in (a) and as shown in (a) Figure 4 The optical roller 2042 shown in (b) is shown in the middle.

[0079] like Figure 4 As shown, the microstructure roller 2031 and the smooth roller 2032 have the same wheel diameter and width, and both have symmetrical journals on both sides of their wheel bodies. The difference between the two is that the outer circular surface of the microstructure roller 2031 has a pre-formed convex ridge structure that can construct a microgroove structure, while the outer circular surface of the smooth roller 2032 is a semi-circular arc surface with a diameter equal to the width of the wheel body. When only microstructures need to be processed on one side of the blade, the rollers 204 mounted on the two supports are the microstructure roller 2041 and the smooth roller 2042, respectively. The microstructure roller 2041 is used to roll and form the microgroove structure on the blade surface, and the smooth roller 2042 is used to provide support force at the symmetrical position on the other side of the blade, reducing blade deformation and strengthening the blade surface. When microstructures need to be processed on both sides of the blade, the rollers 204 mounted on the two supports are both microstructure rollers 2041. When both sides of the blade need to be rolled and strengthened, the rollers 204 mounted on the two supports are both smooth rollers 2042.

[0080] An adjustable clamping force clamping mechanism is used to provide a mounting base for the rolling unit, generate and transmit clamping force to the rolling unit, so that the rolling unit clamps the curved thin-walled blade.

[0081] like Figure 1 , 3As shown, the clamping force adjustable clamping mechanism includes a clamping force transmission mechanism and a force source assembly. The clamping force transmission mechanism includes a first bracket 202 and a second bracket 203 hinged in the middle. 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 are arranged opposite to each other. The force source assembly is located at the rear end 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 to generate an adjustable clamping force. In order to amplify the clamping force generated by the force source assembly, the hinge point 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 machined with a first stepped surface 2022. A first bearing hole 2021 is formed on the high plane of the first stepped surface 2022 along the length of the first bracket 202. A first pin hole 2023 and two first bolt through holes 2024 are provided on the low plane of the first stepped surface 2022, with the first pin hole 2023 located between the two first bolt through holes 2024. A vertically penetrating relief is provided on the outer wall of the first bracket 202 at a certain distance from the first stepped surface 2022. The groove 2025 provides operating space for bolt connections; the rear end of the first bracket 202 has three vertically equidistant connecting holes 2026; more 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 part of the inner side of the bracket arm of the first bracket 202 has a circumferential structure 2027, the inner diameter of the circumferential structure 2027 is larger than the diameter of the cutter shaft 2011 so that the two can rotate relative to each other.

[0083] The structure of the second support 203 is similar to that of the first support 202, except that the circumferential structure on the second support is located on the lower half of the inner side of the support arm, and is adapted to the circumferential structure 2027 on the first support 202. After the circumferential structure 2027 of the first support 202 and the circumferential structure of the second support 203 are aligned vertically, the cutter shaft 2011 is passed through the circumferential structure of the second support 203 and the circumferential structure 2027 of the first support 202 in sequence, thereby hinged the first support 202 and the second support 203 at the middle.

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

[0085] The force source assembly includes a spring 208, connecting rods 209, and a stop block 210. Spring 208 provides the clamping force required for microstructure rolling. There are three connecting rods 209 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 support 202 and the connecting hole on the rear end of the second support 203 to ensure that the connecting rods and connecting holes do not interfere when the angle between the first and second supports increases within a certain angle; each connecting rod 209 has external threads machined at both ends; the three connecting rods 209 pass through the three connecting holes on the rear ends of the first support 202 and the second support 203, respectively. There are three springs 208, each sleeved around one of the three connecting rods 209, and all located between the first support 202 and the second support 203. There are three sets of stop blocks 209, two in each set, which are installed at the external threads at both ends of the connecting rod 209 and threaded together to limit the movement of the connecting rod 209 along the axis of the connecting hole 2026 on the bracket. By adjusting the distance between the two stop blocks 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 at the rear end of the first bracket 202 and the second bracket 203. When the stop blocks 209 are adjusted so that the opening angle of the first bracket 202 and the second bracket 203 gradually increases from zero, the included angle between the connecting hole 2026 at the rear end of the first bracket 202 and the connecting hole at the rear end of the second bracket 203 also gradually decreases from parallel (180 degrees). The gap between the connecting rod 209 and the connecting hole 2026 also becomes smaller and smaller until they come into contact, and the opening angle of the first bracket 202 and the second bracket 203 reaches its maximum value.

[0086] Since the function of spring 208 is to provide clamping force, the parameters of 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 its range of variation. That is to say, the number and placement of spring 208 are not limited to the forms described in this embodiment, but are diverse: for example, only one spring 208 can be provided, and considering the force balance of the device, the spring should be fitted onto the connecting rod 209 located in the middle; two springs 208 can also be provided, and considering the force balance of the device, the two springs should be fitted onto the two connecting rods 209 located on the upper and lower sides respectively. Adaptably, the number of connecting holes at the rear ends of the first bracket 202 and the second bracket 203 is not limited to three, nor is the number of connecting rods 209 limited to three, but is adaptively adjusted and designed according to the required number and placement of spring 208.

[0087] In addition, the distance from the roller 204 installed at the front end of the bracket to the cutter shaft 2011 is less than the distance from the spring 208 located at the rear end of the bracket to the cutter shaft 2011, thereby amplifying the elastic force of the rear spring 208, and the force exerted by the rollers 204 on both sides of the front end on the blade profile is equal, so as to reduce blade deformation.

[0088] The limiting connection assembly includes roller covers 206, end caps 207, and bearings 205. There are two roller covers 206, which respectively mate with the front ends of the first bracket 202 and the second bracket 203, for positioning and mounting the two rollers 204 located at the front ends of the first bracket 202 and the second bracket 203. The end caps 207 restrict the first bracket 202 and the second bracket 203, preventing them from moving vertically and limiting their swing range. There are four bearings 205, respectively mounted on the two roller covers 206, the first bracket 202, and the second bracket 203, for providing support for the rollers 204 of the rolling unit and ensuring their rotation.

[0089] like Figure 5 As shown, taking the roller cover 206 that cooperates with the first bracket 202 as an example, the end face of the roller cover 206 is machined with a second stepped surface 2062 that matches the first stepped surface 2022 at the front end of the first bracket 202, a second bearing hole 2061 that matches the first bearing hole 2021 on the first bracket 202, and a second pin hole 2063 and a second bolt through hole 2064 that match the first pin hole 2023 and the first bolt through hole 2024 on the first bracket 202, respectively; a bearing 205 is installed in both the first bearing hole 2021 and the second bearing hole 2061. After the roller cover 206 is connected to the first bracket 202, the positioning accuracy of the roller 204 and the coaxiality of its two journals can be ensured by the cooperation between the second stepped surface 2062 and the first stepped surface 2022, and by the insertion of positioning pins in the second pin hole 2063 and the first pin hole 2023; by the insertion of bolts in the second bolt through hole 2064 and the first bolt through hole 2024, the tightness of the connection can be ensured.

[0090] After assembly, the journals on both sides of the roller 204 are respectively fitted with the inner rings of the bearings 205 on the roller cover 206 and the bearings 205 on the bracket. The bearings 205 are selected as deep groove ball bearings, which can withstand radial forces but cannot withstand large axial forces; the inner rings 2043 of the shoulders on both sides of the roller 204 contact the end faces of the two bearings 205 respectively to achieve the positioning of the bearings 205; the outer rings 2044 of the shoulders on both sides of the roller 204 contact the top surfaces of the first bearing hole 2021 and the second bearing hole 2061 respectively to restrict the axial movement of the roller 204 and prevent the bearings 205 from bearing axial forces; the length of the journals on both sides of the roller 204 should be greater than the width of the bearings 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 cap 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 is in contact with the top surface of the first bracket 202 and the second bracket 203; the middle part of the horizontal end cap 2071 is provided with a through hole 2073 for the tool shaft 2011 to pass through; the bottom surface of the vertical boss 2072 is in contact with 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 inserting bolts into the first bolt through hole 2015 and the second bolt through hole 2074, the end cap 207 can be fixedly connected to the tool setting platform 2012. Furthermore, the vertical boss 2072 is a certain distance from the side of the second support 203 (this invention has no special requirements for this distance; it mainly ensures that the second support 203 has the required range of rotation, and the larger the required range of rotation, the larger this distance). This allows the second support 203 to have 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 that it has a certain degree of adaptability to changes in the curvature of the blade surface. Since the first support 202 and the second support 203 rotate synchronously during operation, the swing freedom of the first support 202 is limited by the swing freedom of the second support 203.

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

[0093] A spring 208 is placed between the rear end of the first support 202 and the rear end of the second support 203. The original length of the spring 208 is greater than the maximum distance between the rear ends of the device. Under the action of the spring force of the spring 208, the distance between the rear ends always remains at the maximum value, while the front end of the device is completely clamped. The function of the stop block 210 is to control the maximum distance between the rear ends of the first support 202 and the second support 203, so as to control the minimum distance between the front ends of the first support 202 and the front ends of the second support 203. Adjusting the distance of the stop block 210 increases the compressed length of the rear spring 208. At this time, the distance between the front ends of the device is greater than zero but still less than the blade thickness. The device is in force balance under the action of the stop block 210. That is, the elastic force of the spring 208 on the inner rear end of the first support 202 and the second support 203 is balanced with the supporting force of the stop block 210 on the outer rear end of the first support 202 and the second support 203. At this time, the distance between the rear ends of the first support 202 and the second support 203 is adjusted to continue to decrease until the distance between the front ends of the first support 202 and the second support 203 is greater than the blade thickness. The blade is placed between the two rollers. Adjusting the stop block 210 increases the distance between the rear ends of the first support 202 and the second support 203. Correspondingly, the distance between the front ends of the first support 202 and the front ends of the second support 203 will decrease until the two rollers at the front ends completely clamp the blade. Further force analysis of the first support 202 and the second support 203 reveals that the forces exerted on the blade surface by the rollers at the front end and the elastic force of the spring 208 at the rear end are balanced. Furthermore, since the spring forces applied to the inner sides of the first support 202 and the second support 203 are of equal magnitude, the forces exerted on the blade surface by the rollers on both sides are also equal. Therefore, increasing the blade thickness leads to an increase in the front-end spacing and a decrease in the rear-end spacing, compressing the spring 208 and increasing the clamping force. In other words, during rolling, the clamping force increases with increasing blade thickness (increased front-end spacing).

[0094] Example 2:

[0095] like Figure 7 As shown, this embodiment is based on the same principle as Embodiment 1. The only structural difference is that the spring 207 of the clamping mechanism with adjustable clamping force in Embodiment 1 is replaced with a cylinder 211. At the same time, a pneumatic device is added to drive the cylinder 211. The cylinder 211 controls the clamping and opening angles of the first bracket 202 and the second bracket 203 and provides the clamping force required for microstructure rolling. After replacing the spring 208 with the cylinder 211, the connecting rod 208 and the stop block 209 are no longer needed. Only the structure of the rear end of the first bracket 202 and the second bracket 203 needs to be adapted and some accessories need to be added to realize the installation and use of the cylinder 211.

[0096] Specifically, such as Figure 7As shown, in this embodiment, the force source components (spring 207, connecting rod 208 and stop block 209) in Embodiment 1 are removed, and a new force source component is added. The new force source component includes a cylinder 211, a floating joint 212, a connector 213, a pin 214 and a pneumatic device. At the same time, the structure of the rear end 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 Figure 10 As shown, the end face of cylinder 211 has multiple through holes, and there are threads of a certain length on both sides of the through holes. A piston rod extends from one end face of cylinder 211, and the end face of the piston rod has a threaded hole. The floating joint 212 is used to eliminate the axial off-center load on the piston rod of cylinder 211, such as... Figure 11 As shown, one end of the floating joint 212 is a threaded rod, which is threadedly connected to a threaded hole on the piston rod end face of the cylinder 211. The other end of the floating joint 212 has a larger diameter and a threaded hole on its end face. The connector 213 is used to connect the floating joint 212 and the transmission bracket 215, as shown... Figure 12 As shown, one end of the connector 213 is an externally threaded rod, which is used to connect to the threaded hole of the floating connector 212. A hinge hole is provided on the middle side wall of the connector 213.

[0098] like Figure 8 As shown, the front end and middle part of the cylinder bracket 216 have the same structure as the corresponding part of the second bracket 203 in Embodiment 1. 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. The middle part of the connecting boss 2161 is provided with a countersunk piston rod through hole 2162 for the piston rod of the cylinder 211 to pass through. The edge of the connecting boss 2161 is provided with a countersunk bolt through hole 2163 that matches the threaded hole on the end face of the cylinder 211. Bolts can be inserted into the threaded hole on the end face of the cylinder 211 and the countersunk bolt through hole 2163 of the connecting boss 2161 to fix the cylinder 211 on the cylinder bracket 216.

[0099] like Figure 9As shown, the front and middle parts of the transmission bracket 215 are structurally identical to the corresponding parts of the first bracket 202 in Embodiment 1. 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 located on the rear end face of the transmission bracket 215 and extends through the width of the transmission bracket 215. The sliding groove 2152 is formed on the side wall of the connecting groove 2151 and extends through it. One end of the connector 213 is placed in the connecting groove 2151. The diameter of the hinge hole in the middle 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. A pin 214 is installed in the hinge hole in the middle of the sliding groove 2152 and the connector 213, so that the connector 213 can be hinged to the rear end of the transmission bracket 215. The end of the pin 214 is fixed with a cotter pin, and the axial movement of the pin 214 is restricted by the cotter pin.

[0100] After assembly, the centers of the piston rod of cylinder 211, roller 204 and connecting groove 2151 are located on the same horizontal plane, ensuring that the torque on the clamping and rolling device 200 is in the same plane.

[0101] The pneumatic device is a conventional unit, including an air compressor, a pneumatic triplet, a solenoid valve, a one-way throttle valve, a DC power supply, and a switch. The air compressor provides air to cylinder 211; the pneumatic triplet includes an air filter, a pressure reducing valve, and an oil mist lubricator; the air filter cleans the air source by filtering out moisture from the compressed air; the pressure reducing valve stabilizes the air source pressure, adjusting it to a specified pressure; the oil mist lubricator lubricates the pneumatic components; the solenoid valve controls the extension, retraction, and neutral stop of the piston rod of cylinder 211 to control the clamping and opening angles of the clamping roller device 200; the one-way throttle valve adjusts the speed of the piston rod extension and retraction of cylinder 211 to control the clamping and opening speeds of the clamping roller device 200; the DC power supply powers the solenoid valve; the switch controls the power supply status of the DC power supply to the solenoid valve; the air circuit is connected in the order of air compressor, pneumatic triplet, solenoid valve, one-way throttle valve, and cylinder 211; the electrical circuit is connected in the order of DC power supply, switch, and solenoid valve.

[0102] Reference Figure 7 and Figure 13 The working principle and process of this embodiment are as follows:

[0103] When the piston rod of cylinder 211 extends, the angle between the front end of transmission bracket 215 and cylinder bracket 216 decreases, and pin 214 slides backward in slide groove 2152 until pin 214 abuts against the rear wall of slide groove 2152. At this time, clamping rolling device 200 clamps tightly. When the piston rod of cylinder 211 retracts, the angle between the front end of clamping rolling device 200 increases, and pin 214 slides forward in slide groove 2152 until pin 214 reaches the front end of slide groove 2152. At this time, the angle between the front end of clamping rolling device 200 reaches its maximum value. By changing the position and length of slide groove 2152, the maximum value of the distance between the front ends of clamping rolling device 200 can be changed to accommodate blades of different sizes.

[0104] Compared with Embodiment 1, in this embodiment, since the force source component uses a cylinder to generate clamping force, the clamping force of the clamping roller device 200 can be more accurately and conveniently controlled by adjusting the air pressure value inside 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 device's clamping force.

[0105] Example 3:

[0106] like Figure 14 As shown, this embodiment provides a microstructure rolling device for curved thin-walled blade surfaces, including a five-axis CNC machine tool 100 and the clamping rolling device 200 in Embodiment 1.

[0107] A five-axis CNC machine tool 100 is used to control the forming trajectory of micro-structured 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 mount the clamping and rolling device 200. The machine tool work platform 102 is used to clamp the curved thin-walled blade to be processed.

[0108] Example 4:

[0109] This embodiment provides a microstructure rolling device for curved thin-walled blade surfaces, including a five-axis CNC machine tool 100 and the clamping rolling device 200 in Embodiment 2.

[0110] A five-axis CNC machine tool 100 is used to control the forming trajectory of micro-structured 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 mount the clamping and rolling device 200. The machine tool work platform 102 is used to clamp the curved thin-walled blade to be processed.

[0111] Example 5:

[0112] like Figure 15 As shown, this embodiment provides a method for microstructure rolling of a blade surface using the microstructure rolling device of the curved thin-walled blade in Embodiment 3, specifically including the following steps:

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

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

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

[0116] A model of a five-axis CNC machine tool 100 is created. The main features of the five-axis CNC machine tool model include the machine tool spindle 101 and the machine tool work platform 102.

[0117] Models of each component in the clamping rolling device 200 are created, and models of standard parts such as bolts, nuts and spring washers are exported. The component models and standard parts models are assembled to obtain the clamping rolling device model.

[0118] Step 1.1.2: Establish the blade model.

[0119] Step 1.2: Compile the microstructure rolling toolpath program and perform simulation analysis of the machining process;

[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 aerodynamic performance improvement requirements;

[0121] Step 1.2.2 Generate the NC file of the rolling toolpath based on the groove trajectory curve to be processed;

[0122] Based on the shape and position of the groove trajectory curve to be processed and the curvature variation trend of the blade model surface, a suitable tool axis vector, tool advance / retreat method, and feed rate are initially selected, and a tool path is generated. Considering that the tool position point of the clamping and 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 path is offset according to the distance from the contact point between the microstructure roller 2041 and the blade model to the tool position point, thereby obtaining a rolling tool path suitable for the clamping and rolling device 200. The rolling tool path is then post-processed for the control system used by the five-axis CNC machine tool 100 to obtain an NC file (numerical control program file).

[0123] Step 1.2.3 Import the microstructure rolling device model and blade model into the machining 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 each coordinate axis and spindle component. Import the clamping and rolling device model as the tool model and the blade model as the workpiece model. Fix the clamping and rolling device model to the machine tool spindle model according to the actual machining process. Clamp the blade model to the machine tool worktable model.

[0125] Step 1.2.4 Perform simulation analysis of the processing procedure;

[0126] Import the NC file for machining process simulation analysis, observing whether the microstructure rolling device model interferes or collides with the blade model during the simulation. If interference or collision occurs, optimize the tool axis vector, tool entry and exit methods, etc., of the microstructure rolling model until no problems occur, ensuring the safety of the NC file program. Finally, export the confirmed safe NC file for actual rolling processing.

[0127] Step 2: Preparations before processing;

[0128] Step 2.1 Import the confirmed 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 worktable 102;

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

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

[0132] Depending on the specific location of the microstructure groove to be processed, a microstructure roller 2041 is installed on one side of the clamping rolling device 200, and a smooth roller 2042 is installed on the other side; if microstructure grooves are to be symmetrically constructed on both sides of the blade 300, then microstructure rollers 2041 are installed on both sides.

[0133] The journals on both sides of the roller 204 are interference-fitted with the two bearings 205, and the end faces of the bearings 205 are in contact with the inner ring faces of the shoulders of the roller 204; the outer ring of one bearing 205 is clearance-fitted with the first bearing hole 2021 of the first bracket 202, and the outer ring of the other bearing 205 is clearance-fitted with the second bearing hole 2061 of the roller cover 206; the first stepped surface 2022 and the second stepped surface 2062 are aligned; the pin connection adopts an interference fit, and the first pin hole 2023 is used. A positioning pin is placed in the second pin hole 2063; the bracket and roller cover 206 are fastened, the first stepped surface 2022 and the second stepped surface 2062 are in contact with each other, 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; bolts are placed in the two pairs of first bolt through holes 2024 and second bolt through holes 2064, spring washers are placed through the relief groove 2025 and nuts are tightened 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 cap, and tool holder;

[0136] First, connect the second bracket 203 to the tool bar 201 via the tool shaft 2011. The bottom surface of the second bracket 203 contacts the top surface of the tool setting platform 2012. Then, install the first bracket 202 onto the tool bar 201 in the same manner.

[0137] The end cap 207 is connected to the tool shank 201 through the through hole 2073 with a clearance fit to 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 cap 207 is in contact with the top surface of the first bracket 202 and the second bracket 203. 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 in the groove 2014 on one side of the bottom surface of the tool setting platform 2012 and the nut is tightened. The bolt connection restricts the axial movement of the first bracket 202 and the second bracket 203 along the tool shaft 2011.

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

[0139] Based on the mapping relationship between working load and microgroove depth in the previous test data, the deformation range of spring 208 is calculated by measuring the thickness range of blade 300. At the same time, considering the amplification factor of the elastic force of spring 208 by clamping and rolling device 200, springs 208 with appropriate quantity, elastic coefficient and original length are selected and installed.

[0140] Install the spring 208 between the two corresponding connection holes on the first bracket 202 and the second bracket 203. After passing the connecting rod 209 through the spring 208 and the corresponding connection holes on the rear ends of the first and second brackets, install two stop blocks 210 at both ends of the connecting rod 209 by threaded connection. The stop blocks 210 contact the outer surfaces of the two brackets.

[0141] Adjust the distance between the two stops 209 to decrease, thereby increasing the distance between the two rollers 204 at the front end of the support so that it is greater than the thickness of the blade 300;

[0142] Step 2.4 Fix the clamping and rolling device 200 onto the machine tool spindle 101 and use an automatic tool setter to set the tool;

[0143] Step 3: Execute the NC file for tool 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, so as to ensure that the clamping and rolling device 200 will not interfere with the blade 300 during the feed process.

[0145] Step 4: Roll microstructure grooves onto the blade surface;

[0146] The clamping rolling device 200 descends to the starting position of the microstructure groove curve. The spacing of the stop blocks 209 is adjusted so that the clamping rolling device 200 clamps the blade 300. Under the action of clamping force, the microstructure roller 2041 rolls the microstructure groove on the surface of the blade 300 according to the expected trajectory. 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 blade;

[0148] Adjust the distance between the two stops 209 to increase the distance between the two rollers 204 at the front end of the support so that it is greater than the thickness of the blade 300, and complete the blade retraction.

[0149] Example 6:

[0150] like Figure 15 As shown, this embodiment provides a method for microstructure rolling of a blade surface using the microstructure rolling device of the curved thin-walled blade in Embodiment 4, specifically including the following steps:

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

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

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

[0154] A model of a five-axis CNC machine tool 100 is created. The main features of the five-axis CNC machine tool model include the machine tool spindle 101 and the machine tool work platform 102.

[0155] Models of each component in the clamping rolling device 200 are created, and models of standard parts such as bolts, nuts and spring washers are exported. The component models and standard parts models are assembled to obtain the clamping rolling device model.

[0156] Step 1.1.2: Establish the blade model.

[0157] Step 1.2: Compile the microstructure rolling toolpath program and perform simulation analysis of the machining process;

[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 aerodynamic performance improvement requirements;

[0159] Step 1.2.2 Generate NC files based on the groove trajectory curve to be processed;

[0160] Based on the shape and position of the groove trajectory curve to be processed and the curvature variation trend of the blade model surface, a suitable tool axis vector, tool advance / retreat method, and feed rate are initially selected, and a tool path is generated. Considering that the tool position point of the clamping and 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 path is offset according to the distance from the contact point between the microstructure roller 2041 and the blade model to the tool position point, thereby obtaining a rolling tool path suitable for the clamping and rolling device 200. The rolling tool path is then post-processed for the control system used by the five-axis CNC machine tool 100 to obtain an NC file (numerical control program file).

[0161] Step 1.2.3 Import the microstructure rolling device model and blade model into the machining 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 each coordinate axis and spindle component. Import the clamping and rolling device model as the tool model and the blade model as the workpiece model. Fix the clamping and rolling device model to the machine tool spindle model according to the actual machining process. Clamp the blade model to the machine tool worktable model.

[0163] Step 1.2.4 Perform simulation analysis of the processing procedure;

[0164] Import the NC file for machining process simulation analysis, observing whether the microstructure rolling device model interferes or collides with the blade model during the simulation. If interference or collision occurs, optimize the tool axis vector, tool entry and exit methods, etc., of the microstructure rolling model until no problems occur, ensuring the safety of the NC file program. Finally, export the confirmed safe NC file for actual rolling processing.

[0165] Step 2: Preparations before processing;

[0166] Step 2.1 Import the confirmed 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 worktable 102;

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

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

[0170] Depending on the specific location of the microstructure groove to be processed, a microstructure roller 2041 is installed on one side of the clamping rolling device 200, and a smooth roller 2042 is installed on the other side; if microstructure grooves are to be symmetrically constructed on both sides of the blade 300, then microstructure rollers 2041 are installed on both sides.

[0171] The journals on both sides of the roller 204 are interference-fitted with the two bearings 205, and the end faces of the bearings 205 are in contact with the inner ring faces of the shoulders of the roller 204; the outer ring of one bearing 205 is clearance-fitted with the first bearing hole 2021 of the first bracket 202, and the outer ring of the other bearing 205 is clearance-fitted with the second bearing hole 2061 of the roller cover 206; the first stepped surface 2022 and the second stepped surface 2062 are aligned; the pin connection adopts an interference fit, and the first pin hole 2023 is used. A positioning pin is placed in the second pin hole 2063; the bracket and roller cover 206 are fastened, the first stepped surface 2022 and the second stepped surface 2062 are in contact with each other, 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; bolts are placed in the two pairs of first bolt through holes 2024 and second bolt through holes 2064, spring washers are placed through the relief groove 2025 and nuts are tightened 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] The piston rod of cylinder 211 is passed through the countersunk piston rod through hole 2162 on the connecting boss 2161 at the rear end of cylinder bracket 216 and threadedly connected to one end of floating joint 212; then the threaded hole on the end face of cylinder 211 is aligned with the countersunk bolt through hole 2163 on the end face of connecting boss 2161, and the end face of cylinder 211 is in contact with the outer end face of connecting boss 2161. The bolt is screwed into the threaded hole on the end face of cylinder 211 through the countersunk bolt through hole 2163 on connecting boss 2161 to fix cylinder 211 to cylinder bracket 216.

[0175] Screw the threaded rod at one end of connector 213 into the threaded hole of floating connector 212. Place the other end of connector 213 in the connecting groove 2151 at the rear end of transmission bracket 215, and contact the two side surfaces of connecting groove 2151. Align the hinge hole of connector 213 with the sliding groove 2152 on the side wall of connecting groove 2151. Pass pin 214 through sliding groove 2152 and hinge hole of connector 213, and make clearance fit with both. Fix its shaft end with 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 following order: air compressor, pneumatic triplet, solenoid valve, one-way throttle valve, and cylinder. Connect the circuit in the following order: DC power supply, switch, and solenoid valve. Turn on the air compressor to supply air to the air circuit. Based on the mapping relationship between working load and microgroove depth in the previous test data, combined with the output force curve of cylinder 211 with respect to air pressure, and considering the amplification factor of the output force of the clamping rolling device 200 on cylinder 211, adjust the pressure reducing valve of the pneumatic triplet to make the air pressure in cylinder 211 reach the target value. Then, use the one-way throttle valve to adjust the speed of cylinder extension or retraction to control the clamping and opening speed of the clamping rolling device 200 to meet the requirements.

[0178] By controlling the solenoid valve with a switch, the piston rod of cylinder 211 is retracted, thereby increasing the distance between the two rollers 204 on both sides of the front end of the clamping rolling device 200 to be greater than the thickness of the blade 310.

[0179] Step 4: Roll microstructure grooves onto the blade surface;

[0180] The clamping and rolling device 200 descends to the starting position of the microstructure groove curve. The piston rod of the cylinder 211 is extended by controlling the solenoid valve through a switch. The clamping and rolling device 200 clamps the blade 300. Under the action of the clamping force, the microstructure roller 2041 rolls and forms the microstructure groove on the surface of the blade 300 according to the expected trajectory. 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.

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

[0182] The piston rod of cylinder 211 is retracted by controlling the solenoid valve with a switch, thereby increasing the distance between the rollers 204 on both sides of the front end of the clamping and rolling device to be greater than the thickness of the blade 300, thus completing the blade retraction.

[0183] The above embodiments are merely illustrative examples of machining thin-walled curved blades. It should be noted that the present invention is not only applicable to machining thin-walled curved blades, but also applicable to machining other curved thin-walled parts.

Claims

1. A clamping and rolling device, characterized in that: It includes a connecting unit, a rolling unit, a clamping mechanism with adjustable clamping force, and a limit connecting assembly; The connecting unit is used to connect the clamping and rolling device to the spindle of the five-axis CNC machine tool; the connecting unit includes a tool bar, which is composed of a tool shaft and a tool setting platform connected vertically; the upper part of the tool shaft is used to connect to the spindle of the five-axis CNC machine tool, the lower part of the tool shaft is used to rotatably connect to the clamping mechanism, and the tool setting platform is used to set the tool with the automatic tool setter of the five-axis CNC machine tool; The rolling unit is a microstructure roller group, a smooth roller group, or a roller group composed of microstructure rollers and smooth rollers, used to roll and form microgroove structures on the blade surface, and / or to roll and strengthen the blade surface; A clamping mechanism is used to generate and transmit clamping force to the rolling unit, so that the rolling unit clamps the curved thin-walled part; the middle part of the clamping mechanism is rotatably connected to the connecting unit; the clamping mechanism includes a clamping force transmission mechanism and a force source assembly; the clamping force transmission mechanism includes a first bracket and a second bracket, both of which have a ring structure on their middle inner sidewalls, and both are rotatably connected to the lower part of the cutter shaft through the ring structure, and the ring structures are arranged vertically; the force source assembly is located at the rear end of the first bracket and the second bracket, and is used to generate a controllable force to increase the angle between the rear ends of the first bracket and the second bracket to form the clamping force required for microstructure rolling at the front end of the first bracket and the second bracket; The limiting connection assembly is used to mount the two rollers of the rolling unit opposite to each other at the front end of the clamping mechanism, and to limit the swing range of the clamping mechanism relative to the connecting unit. The limiting connection assembly includes roller covers, end covers, and bearings. There are two roller covers, which respectively mate with the front ends of the first and second supports, for positioning and mounting the two rollers at the front ends of the first and second supports. The end covers limit the position of the first and second supports, preventing vertical movement, and limit the swing range of the first and second supports. The shaft is mounted on the roller covers, the first support, and the second support. The end cap is used to support the rollers; the end cap includes a horizontal cover plate and a vertical boss located on one side of the horizontal cover plate; the bottom surface of the horizontal cover plate contacts the top surface of the first bracket and the second bracket; the middle of the horizontal end cap is provided with a through hole for the cutter shaft to pass through; the bottom surface of the vertical boss contacts the top surface of the tool setting platform, and the vertical boss is provided with a second bolt through hole corresponding to the first bolt through hole on one side of the tool setting platform. By inserting bolts into the first bolt through hole and the second bolt through hole, the end cap is fixedly connected to the tool setting platform; the vertical boss is a certain distance from the side of the second bracket, so that the second bracket can have a certain range of swing freedom. When the angle at the rear end of the clamping mechanism increases, the angle at its front end decreases, reducing the distance between the two rollers of the rolling unit to clamp the curved thin-walled part; conversely, when the angle at the rear end of the clamping mechanism decreases, the angle at its front end increases, increasing the distance between the two rollers of the rolling unit to release the curved thin-walled part.

2. The clamping and rolling device according to claim 1, characterized in that: The force source assembly includes a spring, a connecting rod, and a stop; 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 ends of the first support and the rear ends of the second support; the connecting rod is used to install the spring between the inner sidewalls of the rear ends of the first support and the second support; the stop is installed on the connecting rod and located outside the first and second supports. By adjusting the position of the stop on the connecting rod, the distance between the rear ends of the first support and the rear ends of the second support can be controlled, thereby adjusting the clamping force.

3. The clamping and rolling device according to claim 2, characterized in that: The number of springs, the elastic coefficient of a single spring, and the original length are selected and combined according to the magnitude and range of the required clamping force.

4. The clamping and rolling device according to claim 1, characterized in that: The power source assembly includes a cylinder, a floating joint, and a connector connected in sequence, and also includes a pneumatic device for driving the cylinder. After the piston rod of the cylinder passes through the rear end of the first bracket / 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 machined on the side wall of the other end of the connector, and this end of the connector is inserted into the connecting groove on the rear end of the second bracket / first bracket. By inserting a pin into the connecting groove and the hinge hole, the end of the connector is hinged to the rear end of the second bracket / first bracket. 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, thereby adjusting the clamping force.

5. A microstructure rolling device for curved thin-walled parts, comprising a five-axis CNC machine tool; characterized in that: It also includes the clamping and rolling device according to any one of claims 1-4; the clamping and rolling device is installed on the spindle of the five-axis CNC machine tool.

6. A method for rolling microstructures on the surface of a curved thin-walled part using the clamping rolling device according to any one of claims 1-4, characterized in that, Includes the following steps: Step 1: Modeling and simulation of the manufacturing process; Step 1.1 Establish the microstructure rolling device model and blade model; Step 1.2: Compile the microstructure rolling toolpath program and perform simulation analysis of the machining process; 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 aerodynamic performance improvement requirements; Step 1.2.2 Generate the NC file of the rolling toolpath based on the groove trajectory curve to be processed; Step 1.2.3 Import the microstructure rolling device model and blade model into the machining simulation software and assemble them; Step 1.2.4 Perform a simulation analysis of the machining process to obtain the NC file after confirming safety; Step 2: Preparations before processing; Step 2.1 Import the confirmed 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 worktable; Step 2.3 Fix the clamping and rolling device onto the machine tool spindle and use an automatic tool setter to set the tool; Step 3: Execute the NC file for tool 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, so as to ensure that the clamping and rolling device will not interfere with the curved thin-walled part to be processed during the feed process; Step 4: Roll microstructure grooves onto the surface of the curved thin-walled part to be processed; The clamping and rolling device is lowered to the starting position of the microstructure groove curve. The front angle of the clamping and rolling device is adjusted to clamp the curved thin-walled part to be processed. Under the action of clamping force, the microstructure roller rolls the microstructure groove on the surface of the curved thin-walled part to be processed along the expected trajectory. 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 reinforcement until the rolling process is completed. or, Under the action of clamping force, the microstructure rollers on both sides synchronously roll-form microstructure grooves on both sides of the curved thin-walled part to be processed along the expected trajectory until the rolling process is completed; or, Under the action of clamping force, the two light rollers on both sides synchronously roll and strengthen the curved thin-walled parts on both sides of the part to be processed along the expected trajectory until the rolling process is completed; Step 5: Adjust the roller spacing and retract the blade; Adjust the front angle of the clamping and rolling device to increase the distance between the two rollers at the front of the support so that it is greater than the thickness of the curved thin-walled part to be processed, and complete the tool retraction.

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