Blade machining system and method

Abstract

The invention relates to the technical field of blade machining, and discloses a blade machining system and method.The system comprises a mechanical drive polishing and grinding system, a blade body clamping system and a blade body; the blade body clamp is arranged on the blade body clamping system, and a blade body is driven by the blade body clamping system to move in the circumferential direction. The mechanical drive polishing and grinding system is located on one side of the blade body clamping system, and the polishing and grinding end of the mechanical drive polishing and grinding system makes contact with the blade body, moves along the overall structure face of the blade body and is used for polishing and grinding the overall structure of the blade body. According to the method, it can be ensured that the polishing and grinding end touches all parts of the blade body, so that polishing and grinding of the whole structure of the blade body are achieved, the limitation of a traditional polishing and grinding mode is broken through, and the requirement for machining of the whole blade body of a complex blade is met.

Description

Technical Field

[0001] The present invention relates to the technical field of blade processing, and in particular to a blade processing system and method. Background Art

[0002] With the rapid development of aviation technology, the performance of aircraft engines, as core components, is directly related to the overall performance of aircraft. As a key component of the engine, the structural complexity of engine blades is constantly increasing with the continuous advancement of aviation technology.

[0003] In the manufacturing process of engine blades, polishing is a crucial step in ensuring surface quality, dimensional accuracy, and overall performance. Currently, the industry generally uses a robot to hold the blades for polishing. However, this traditional method has exposed significant limitations when faced with increasingly complex blade structures.

[0004] Due to the diverse and irregular shapes, curved surfaces, and edge structures of complex blades, the polishing method using a robot to grip the blade is difficult to effectively process the entire blade body. Specifically, when machining areas with deep cavities, complex curved surfaces, or special angles, the robot's motion trajectory and the accessibility of the polishing tool are greatly limited, resulting in these critical areas being unable to receive sufficient and accurate polishing. This not only affects the surface integrity and dimensional accuracy of the blade, but can also adversely affect the blade's aerodynamic performance, strength, and service life.

[0005] Furthermore, the inability to fully machine the blade body severely restricts blade production efficiency. During production, to meet blade quality requirements, unprocessed areas often require additional processing, or poor machining can increase blade scrap rates, increasing production costs and cycle times. Therefore, developing a machining technology that can effectively handle complex blade structures and achieve full blade body machining is of great practical significance for improving the production efficiency and quality of aero-engine blades and promoting the development of aviation technology. Summary of the Invention

[0006] In order to overcome the above-mentioned defects of the prior art, the purpose of the present invention is to provide a blade processing system and method to solve the technical problem in the prior art that the overall processing efficiency of complex blade structures cannot be improved.

[0007] The present invention is achieved through the following technical solutions: In a first aspect, the present invention provides a blade processing system, comprising a mechanically driven polishing system, a blade body clamping system, and a blade body; The blade body clamp is arranged on a blade body clamp system, and the blade body is driven to perform circumferential motion by the blade body clamp system; The mechanically driven polishing system is located on one side of the blade clamping system. The polishing end of the mechanically driven polishing system contacts the blade and moves along the overall structural surface of the blade to polish the overall structure of the blade.

[0008] Preferably, the mechanically driven polishing system includes a six-axis manipulator, a power spindle head and a polishing head; The six-axis manipulator is located on one side of the blade clamping system, the power shaft head is installed at the swing end of the six-axis manipulator, and the polishing head is assembled on the driving end of the power shaft head. The six-axis manipulator drives the polishing head through the power shaft head to contact the blade and move along the overall structural surface of the blade; the power shaft head drives the polishing head to perform circumferential motion.

[0009] Furthermore, the type of the polishing head 3 is arranged corresponding to the blade structure, wherein the types of the polishing head include a flat-head polishing head and a hemispherical polishing head.

[0010] Furthermore, damping platforms are provided on both sides of the blade 4, the damping platforms are arranged perpendicular to the blade and form an arc-shaped connection angle at the connection with the blade; the polishing end of the flat-head polishing head contacts the surface of the damping platform.

[0011] Furthermore, an angle is provided between the polishing end of the flat-head polishing head and the surface of the damping platform.

[0012] Furthermore, the hemispherical polishing head contacts the blade, the connection between the blade and the damping platform, and the connection between the bottom of the blade and the blade clamping system.

[0013] Preferably, the blade body clamping system includes a tenon fixture, a work turntable and a processing table; The working turntable is rotatably arranged on the processing table, the tenon clamp is arranged at the center of the working turntable, the bottom of the blade body is clamped on the tenon clamp, and the working turntable drives the blade body to perform circumferential motion through the tenon clamp.

[0014] In a second aspect, the present invention further provides a blade processing method, based on the blade processing system described above, comprising the following steps: Place the blade on the blade clamping system, and drive the blade to move circumferentially through the blade clamping system; The polishing end of the mechanically driven polishing system is brought into contact with the blade body, and the mechanically driven polishing system is moved along the overall structural surface of the blade body to complete the polishing work of the overall structure of the blade body.

[0015] Preferably, the polishing system includes a six-axis manipulator, a power spindle head and a polishing head; the six-axis manipulator is located on one side of the blade clamping system, the power spindle head is installed at the swing end of the six-axis manipulator, and the polishing head is assembled on the driving end of the power spindle head; The types of polishing heads include flat-head polishing heads and hemispherical polishing heads; When damping platforms are provided on both sides of the blade, the polishing end of the flat-head polishing head is used to polish the surface of the damping platform. The blade, the connection between the blade and the damping platform, and the connection between the bottom of the blade and the blade clamping system are polished using a hemispherical polishing head.

[0016] Furthermore, the circumferential rotation speed of the blade body driven by the blade body clamping system is lower than the rotation speed of the polishing end of the mechanically driven polishing system.

[0017] Compared with the prior art, the present invention has the following beneficial technical effects: The present invention provides a blade processing system that uses a blade clamping system to drive the blade in circumferential motion. Simultaneously, a mechanically driven polishing system moves the polishing tip along the blade's overall structural surface, ensuring that the polishing tip contacts every part of the blade, thereby polishing the entire blade structure. This overcomes the limitations of traditional polishing methods and meets the requirements for full blade processing of complex blades. By achieving full blade polishing, all parts of the blade receive uniform and precise polishing, avoiding problems such as poor surface quality and low dimensional accuracy caused by incomplete polishing of certain areas. This significantly improves the blade's processing quality and ensures its aerodynamic performance, strength, and service life.

[0018] Furthermore, the six-axis robot possesses six degrees of freedom, enabling complex three-dimensional motion. Compared to traditional robots, it can more flexibly adjust the position and posture of the polishing head, easily reaching various parts of the blade, including deep cavities and complex curved transitions that are difficult for traditional polishing equipment to reach. This ensures close contact between the polishing head and the blade, providing a solid motion foundation for full-blade polishing and significantly improving polishing flexibility and accessibility. The power spindle head is mounted at the swing end of the six-axis robot and drives the polishing head in circumferential motion. This allows the polishing head to move along the overall structural surface of the blade while precisely rotating according to the shape and processing requirements of different blade parts, achieving more precise polishing operations, ensuring the uniformity and consistency of the polished surface, and improving polishing quality. Through the coordinated motion of the six-axis robot and the power spindle head, the polishing head can move continuously and efficiently along the overall structural surface of the blade, eliminating the need for frequent equipment adjustments or complex operations, significantly shortening polishing time and improving polishing efficiency. At the same time, since all parts of the blade can be polished, quality defects caused by inadequate polishing of some areas are avoided, ensuring the consistency of the overall processing quality of the blade.

[0019] Furthermore, for the relatively flat, regular plane areas with small curvature in the blade, the flat-head polishing head can fit well with the blade surface. Its large contact area makes the pressure distribution uniform during polishing, and it can cover a large area in one polishing process, effectively removing surface roughness and unevenness, ensuring that the surface of these areas is smooth and the dimensional accuracy meets the requirements, thereby improving the overall polishing quality. There are often some complex curved surfaces in the blade, such as deep cavities, small curvature turning points, etc. The hemispherical polishing head has a rounded shape, which can flexibly adapt to these complex curved surfaces and fit tightly with the blade surface. During the polishing process, it can automatically adjust the contact angle as the blade surface changes, ensuring uniform polishing force, avoiding over-polishing or under-polishing, and effectively improving the polishing accuracy and quality of these complex areas.

[0020] Furthermore, the damping platform is perpendicular to the blade, making the flat-head polishing head more effective for this vertical structure. Compared to polishing heads of other shapes, the flat-head polishing head can act more directly on the damping platform surface, reducing the polishing dead angles caused by structural limitations and ensuring that all parts of the damping platform surface are fully and evenly polished.

[0021] Furthermore, setting the included angle can make the polishing end of the flat-head polishing head contact the table surface of the damping table at a specific angle. This targeted contact method can better adapt to the shape and processing requirements of the damping table surface.

[0022] Furthermore, the connection between the blade and damping platform, as well as the connection between the blade base and the blade clamping system, often has complex geometries, with curved surface transitions and angle changes. The hemispherical polishing head, with its rounded shape, adapts well to these complex curved surfaces and connection structures, fitting closely to them and ensuring that no dead corners are left during the polishing process, thereby improving the comprehensiveness and accuracy of the polishing process.

[0023] Furthermore, a tenon fixture is set at the center of the work turntable, and the bottom of the blade is clamped on the tenon fixture, so that the blade can be accurately positioned through the tenon fixture, ensuring the position accuracy and stability of the blade during the clamping process, providing a reliable foundation for subsequent polishing and other processing steps, reducing processing errors caused by clamping deviations, and improving the processing accuracy of the blade. The work turntable is rotatably set on the processing table and drives the blade to move circumferentially through the tenon fixture, so that the blade can be flexibly rotated according to different processing requirements during the processing process, facilitating the processing of different parts of the blade by processing tools such as polishing heads.

[0024] The present invention also provides a blade processing method, in which the blade body clamping system drives the blade body to perform circumferential motion, so that the blade body can contact the polishing end from various angles during the processing. For the complex curved surface structure of the blade body, it can ensure that the polishing end can accurately fit the surface of the blade body, and whether it is a regular curved surface or an irregular curved surface, uniform and meticulous polishing can be achieved, which greatly improves the processing accuracy of the blade body and reduces the shape error caused by uneven polishing. The blade body is driven to perform circumferential motion by the blade body clamping system, and there is no need to frequently re-clamp the blade body or adjust its position to process different parts. After one clamping, the polishing work of multiple angles of the blade body can be completed, which reduces the clamping and adjustment time and improves the processing efficiency. It is particularly suitable for mass production and can significantly shorten the production cycle.

[0025] Furthermore, when damping platforms are installed on both sides of the blade, a flat-head polishing head is used to polish the corresponding damping platform surfaces. The flat-head polishing head has a flat and regular contact surface, which fits tightly against the damping platform surface. This ensures even pressure distribution during polishing, effectively removes burrs, oxide layers, and other defects on the platform surface, and achieves a high level of surface finish and dimensional accuracy, improving the overall blade processing quality. A hemispherical polishing head is used for polishing the blade, the connection between the blade and the damping platform, and the connection between the blade base and the blade clamping system. Its rounded shape adapts well to these complex curved surfaces and connection structures, conforming tightly to them and avoiding blind spots. This ensures comprehensive and precise polishing of the connection, improves the strength and reliability of the connection, reduces stress concentration points, and extends the blade's service life. Polishing heads are available in both flat and hemispherical styles, allowing for quick switching between different polishing heads depending on the processing area. This rapid switching capability reduces processing downtime caused by tool changes and improves processing efficiency. In batch production, the production cycle can be significantly shortened to meet the needs of large-scale production. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 Schematic diagram of the overall structure of the blade processing system in an embodiment of the present invention; Figure 2 This is a top view of a polishing head polishing a blade according to an embodiment of the present invention; Figure 3 Schematic diagram of polishing heads of different specifications in an embodiment of the present invention; Figure 4 Schematic diagram of the left and right sides of the blade damping platform in an embodiment of the present invention; Figure 5 This is a top view of a polishing head polishing a blade damping platform according to an embodiment of the present invention; Figure 6 Schematic diagram of a polishing head polishing a blade damping platform according to an embodiment of the present invention; Figure 7Schematic diagram of the angle between the blade damping platform and the blade when the polishing head polishes the blade in an embodiment of the present invention; Figure 8 This is a first schematic diagram of a polishing head polishing a blade body and a blade edge plate according to an embodiment of the present invention; Figure 9 This is a second schematic diagram of the polishing head polishing the blade and the edge plate in an embodiment of the present invention; In the figure: 1. Six-axis manipulator; 2. Power spindle head; 3. Polishing head; 4. Blade body; 5. Tenon fixture; 6. Work turntable; 7. Processing table; 8. Damping table. DETAILED DESCRIPTION

[0027] In order to enable those skilled in the art to better understand the solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0028] The object of the present invention is to provide a blade processing system and method to solve the technical problem in the prior art that the overall processing efficiency of complex blade structures cannot be improved.

[0029] The present invention is described in further detail below with reference to the accompanying drawings: See also Figure 1 In one embodiment of the present invention, a blade processing system is provided, including a mechanically driven polishing system, a blade body clamping system and a blade body 4; the blade body 4 is clamped on the blade body clamping system, and the blade body 4 is driven to move circumferentially by the blade body clamping system; the mechanically driven polishing system is located on one side of the blade body clamping system, and the polishing end of the mechanically driven polishing system contacts the blade body 4 and moves along the overall structural surface of the blade body 4, so as to polish the overall structure of the blade body 4.

[0030] Specifically, the mechanically driven polishing system includes a six-axis manipulator 1, a power shaft head 2 and a polishing head 3; The six-axis manipulator 1 is located on one side of the blade clamping system, the power shaft head 2 is installed at the swing end of the six-axis manipulator 1, and the polishing head 3 is assembled on the driving end of the power shaft head 2. The six-axis manipulator 1 drives the polishing head 3 through the power shaft head 2 to contact the blade 4 and move along the overall structural surface of the blade 4; the power shaft head 2 drives the polishing head 3 to perform circumferential motion.

[0031] Specifically, the type of the polishing head 3 corresponds to the blade structure, wherein the types of the polishing head 3 include a flat-head polishing head and a hemispherical polishing head.

[0032] Among them, according to Figure 2 and Figure 4 As shown, damping platforms 8 are provided on both sides of the blade 4. The damping platforms 8 are arranged perpendicular to the blade 4 and form an arc-shaped connection angle with the blade 4; the polishing end of the flat-head polishing head contacts the surface of the damping platform 8.

[0033] Therein, an angle is provided between the polishing end of the flat-head polishing head and the surface of the damping platform 8 .

[0034] The hemispherical polishing head contacts the blade 4, the connection between the blade 4 and the damping platform 8, and the connection between the bottom of the blade 4 and the blade clamping system.

[0035] In this embodiment, the blade body clamping system includes a tenon fixture 5, a work turntable 6 and a processing table 7; The working turntable 6 is rotatably set on the processing table 7, the tenon clamp 5 is set at the center position of the working turntable 6, the bottom of the blade 4 is clamped on the tenon clamp 5, and the working turntable 6 drives the blade 4 to perform circumferential movement through the tenon clamp 5.

[0036] In this embodiment, the high flexibility of the six-axis manipulator 1 is fully utilized. The manipulator is connected to a power spindle head and combined with polishing heads of various specifications to achieve full-blade polishing of complex blades. When polishing the entire blade, an appropriate polishing head is selected based on the curvature of the blade profile and the size of the adapter R. The turntable carries the blade to adjust its position and coordinate with the polishing head for processing. The optimal positioning of the six-axis manipulator and the coordinated use of the polishing heads ensure that the blade can be clamped once and the entire blade body polished. This processing method achieves full-blade processing of complex blades, improving blade processing efficiency while ensuring blade processing quality.

[0037] In this embodiment, a manipulator is connected to a power spindle head, which grasps a polishing head. The manipulator drives the high-speed rotating polishing head to move along the blade surface at a specified pressure to complete the polishing of the blade surface. This processing method ensures efficient and consistent blade surface processing.

[0038] This embodiment uses a six-axis manipulator head connected to a power shaft head, and a polishing head is installed on the power shaft head. The polishing head rotates at high speed under the drive of the power shaft head, and has the ability to polish. The processing method of using a manipulator to drive the polishing head fully utilizes the flexibility of the six-axis manipulator, thereby having the ability to process the entire surface of the blade except the clamping area. The six-axis manipulator head is used to install the power shaft head, and the polishing head is grasped to process the blade. This method can select the best specification polishing head according to the curvature of the blade and the size of the adapter R, so as to realize the polishing of the difficult-to-process surface of the blade. By using the turntable to clamp the blade and rotate the blade, the blade can be placed in the best polishing position, thereby realizing the full blade polishing of the blade. The method used in this embodiment is simple and easy, reduces the cost of blade processing, improves processing efficiency, and effectively solves the processing problems in blade production and manufacturing.

[0039] Example 2 This embodiment further provides a blade processing method, based on the blade processing system described above, including the following process: Placing the blade 4 on the blade clamping system, and driving the blade 4 to perform circumferential motion through the blade clamping system; The polishing end of the mechanically driven polishing system is brought into contact with the blade 4 , and the mechanically driven polishing system is moved along the overall structural surface of the blade 4 to complete the polishing work on the overall structure of the blade 4 .

[0040] Specifically, the mechanically driven polishing system includes a six-axis manipulator 1, a power spindle head 2, and a polishing head 3. The six-axis manipulator 1 is located on one side of the blade clamping system, the power spindle head 2 is installed at the swing end of the six-axis manipulator 1, and the polishing head 3 is assembled on the driving end of the power spindle head 2; The types of the polishing head 3 include a flat head polishing head and a hemispherical polishing head; When damping platforms 8 are provided on both sides of the blade 4, the polishing end of the flat-head polishing head is used to polish the surface of the damping platform 8; The blade 4, the connection between the blade 4 and the damping platform 8, and the connection between the bottom of the blade 4 and the blade clamping system are polished using a hemispherical polishing head.

[0041] In this embodiment, the flat head polishing head and the hemispherical polishing head include specifications of different sizes, such as Figure 3 As shown, select the B1 specification polishing head, rotate the work turntable 6, and the relative position of the polishing head and the blade surface is as follows Figure 2 As shown, the processing of the blade area except the damping platform 8 and the connection between the damping platforms on both sides and the blade surface can be completed.

[0042] Select A2 specification polishing head, rotate the work turntable 6, and the relative position of the polishing head and the blade damping table 8, as shown in the following figure: Figure 5 and Figure 6As shown, when processing the upper and lower surfaces of the damping table, the polishing head needs to form a certain angle with the center line of the damping table. The angles include a1, a2, a3, and a4, and the angles change as the processing proceeds.

[0043] according to Figure 7 As shown, a B4 polishing head with a slightly smaller transition R between the damping platform 8 and the blade body is selected to process the grabbing joint and its vicinity.

[0044] according to Figure 8 and Figure 9 As shown in the figure, the B3 polishing head with a slightly smaller R of the blade and edge plate transition is selected to process the blade and edge plate transition and the upper surface of the edge plate.

[0045] Specifically, the circumferential rotation speed of the blade body 4 driven by the blade body clamping system is lower than the rotation speed of the polishing end of the mechanical drive polishing system.

[0046] In summary, the present invention also provides a blade processing method, in which the blade clamping system drives the blade to perform circumferential motion, so that the blade can contact the polishing end from various angles during the processing. For the complex curved surface structure of the blade, it can ensure that the polishing end can accurately fit the surface of the blade, and whether it is a regular curved surface or an irregular curved surface, uniform and meticulous polishing can be achieved, which greatly improves the processing accuracy of the blade and reduces the shape error caused by uneven polishing. The blade is driven to perform circumferential motion by the blade clamping system, and there is no need to frequently re-clamp the blade or adjust its position to process different parts. After one clamping, the polishing work of multiple angles of the blade can be completed, which reduces the clamping and adjustment time and improves the processing efficiency. It is especially suitable for mass production and can significantly shorten the production cycle.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A blade processing system, characterized in that: It includes a mechanically driven polishing system, a blade body clamping system and a blade body (4); The blade (4) is clamped on a blade clamping system, and the blade (4) is driven to perform circumferential motion by the blade clamping system; The mechanically driven polishing system is located on one side of the blade body clamping system, and the polishing end of the mechanically driven polishing system contacts the blade body (4) and moves along the overall structural surface of the blade body (4) to polish the overall structure of the blade body (4).

2. A blade processing system according to claim 1, characterized in that: The mechanically driven polishing system comprises a six-axis manipulator (1), a power shaft head (2) and a polishing head (3); The six-axis manipulator (1) is located on one side of the blade body clamping system, the power shaft head (2) is installed at the swing end of the six-axis manipulator (1), and the polishing head (3) is assembled on the driving end of the power shaft head (2). The six-axis manipulator (1) drives the polishing head (3) via the power shaft head (2) to contact the blade body (4) and move along the overall structural surface of the blade body (4); the power shaft head (2) drives the polishing head (3) to perform circumferential motion.

3. A blade processing system according to claim 2, characterized in that: The type of the polishing head 3 corresponds to the blade body structure setting, wherein the type of the polishing head (3) includes a flat-head polishing head and a hemispherical polishing head.

4. A blade processing system according to claim 3, characterized in that: Damping platforms (8) are respectively provided on both sides of the blade body 4. The damping platforms (8) are arranged perpendicular to the blade body (4) and form an arc-shaped connection angle at the connection with the blade body (4); the polishing end of the flat-head polishing head contacts the surface of the damping platform (8).

5. A blade processing system according to claim 4, characterized in that: An included angle is provided between the polishing end of the flat-head polishing head and the surface of the damping platform (8).

6. A blade processing system according to claim 3, characterized in that: The hemispherical polishing head contacts the blade (4), the connection between the blade (4) and the damping platform (8), and the connection between the bottom of the blade (4) and the blade clamping system.

7. The blade processing system according to claim 1, characterized in that: The blade body clamping system includes a tenon clamp (5), a work turntable (6), and a processing table (7); The working turntable (6) is rotatably arranged on the processing table (7), the tenon clamp (5) is arranged at the center position of the working turntable (6), the bottom of the blade (4) is clamped and arranged on the tenon clamp (5), and the working turntable (6) drives the blade (4) to perform circumferential movement through the tenon clamp (5).

8. A blade processing method, based on a blade processing system according to any one of claims 1 to 7, characterized in that: The process includes the following: Placing the blade (4) on the blade clamping system, and driving the blade (4) to perform circumferential motion via the blade clamping system; The polishing end of the mechanically driven polishing system is brought into contact with the blade (4), and the mechanically driven polishing system is moved along the overall structural surface of the blade (4), thereby completing the polishing work on the overall structure of the blade (4).

9. A blade processing method according to claim 8, characterized in that: The mechanically driven polishing system comprises a six-axis manipulator (1), a power shaft head (2) and a polishing head (3); the six-axis manipulator (1) is located on one side of the blade body clamping system, the power shaft head (2) is installed at the swing end of the six-axis manipulator (1), and the polishing head (3) is assembled on the driving end of the power shaft head (2); The types of the polishing head (3) include a flat-head polishing head and a hemispherical polishing head; When damping platforms (8) are provided on both sides of the blade (4), the polishing end of the flat-head polishing head is used to polish the surface of the damping platform (8); A hemispherical polishing head is used to polish the blade (4), the connection between the blade (4) and the damping platform (8), and the connection between the bottom of the blade (4) and the blade clamping system.

10. A blade processing method according to claim 9, characterized in that: The blade body clamping system drives the blade body (4) to rotate circumferentially at a speed lower than the rotation speed of the polishing end of the mechanically driven polishing system.

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