Bilateral Ultrasonic Rolling Paths for Blade Deformation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing ultrasonic rolling technology for blade surfaces in engines faces low machining efficiency and poor quality due to the complexity of blade shapes and the need for constant pressure, which can cause deformation and incomplete machining.
Innovation Solution
A machining path coordination method for bilateral ultrasonic rolling that involves layering the blade to obtain contour curves, determining machining path endpoints, and planning rotation angles to synchronize the movement of double machining heads, reducing deformation and improving efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If unilateral ultrasonic surface rolling process is adopted, then the process is simpler to implement, but the machining efficiency is low and constant pressure causes blade deformation
Solution Approach 1:
The blade surface machining is divided into two independent sides (outer arc surface and inner arc surface), each processed by a separate machining head. This segmentation allows both sides to be machined simultaneously, doubling the productivity while maintaining manageable complexity through modular head design
Solution Approach 2:
Two machining heads are combined into a single bilateral processing system that operates simultaneously on both sides of the blade. The merging of processing operations for both surfaces resolves the efficiency limitation of unilateral processing while the coordinated control system manages the added complexity
2Strength
If constant pressure is applied on the blade surface during unilateral rolling, then the surface strengthening effect is achieved, but the blade deformation increases and machining quality deteriorates
Solution Approach 1:
The bilateral processing system applies pressure from both sides of the blade simultaneously, creating counterbalancing forces that offset each other. This counterweight effect eliminates the need for excessive constant pressure on one side, reducing blade deformation while maintaining effective surface strengthening through coordinated dual-sided loading
3Extent of automation
If the rotation angle of the blade is not reasonably coordinated during bilateral rolling, then the machining heads move synchronously, but the machining head may cover the inner area or not reach the endpoint resulting in incomplete machining
Solution Approach 1:
The blade rotation angle is transformed from a static fixed value to a dynamic variable that changes continuously during the machining process. The rotation angle adjusts in real-time based on the position of the machining heads, ensuring that both heads reach their respective endpoints simultaneously and accurately cover the entire required machining area without overlap or gaps
Solution Approach 2:
The system incorporates feedback control where the actual positions of the machining heads are continuously monitored and used to adjust the blade rotation angle in real-time. This feedback mechanism ensures that the theoretical synchronous movement translates into accurate practical machining coverage, preventing both heads from missing endpoints or overlapping incorrectly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances machining efficiency and accuracy by coordinating the movement of machining heads on both sides of the blade, ensuring complete coverage and minimizing deformation, thereby improving the surface quality of the blade.
Implementation Method 1
The ultrasonic rolling technology uses the combination of ultrasonic impact power and static load rolling to impact the surfaces of metal parts at a high speed
Implementation Method 2
produce larger plastic deformation on the surface material of the parts and form beneficial residual compressive stress after unloading
Data Source
AI summary
Provided is a bilateral ultrasonic rolling processing track coordination method for a blade surface, the method comprising: step S1, performing layering processing on a blade to acquire a contour curve of “A”-shaped and “n”-shaped blade edges of a blade model at different heights; step S2: determining the endpoints of a blade processing track; and step S3: planning the thickness and the rotation angle of the blade, comprising: step S31, solving a main direction angle αmain of the contour curve; step S32, solving the thickness d of the blade; step S33, solving a rotation angle required by blade processing when the blade edge is “A”-shaped; and step S34, solving the rotation angle required by blade processing when the blade edge is “n”-shaped. According to the method, blade deformation generated by an ultrasonic rolling force is reduced, the processing efficiency is improved, and the blade processing precision is also improved.