Robot Ultrasonic Rolling of Aircraft Blades With Flexible Follow-Up Support
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Solution Overview
Problem
Conventional CNC machining methods struggle to perform accurate and effective ultrasonic surface rolling on aircraft engine blades due to blade flutter and deformation caused by high-amplitude and high-frequency ultrasonic vibration, affecting the surface modification and geometric accuracy.
Innovation Solution
A robot machining system with a flexible follow-up support head and a three-dimensional mobile lifting device is used to control the ultrasonic surface rolling process, ensuring the force exerted on the blade is uniform and minimizing deformation and flutter, utilizing a five-axis or six-axis robot for precise machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional CNC machining method is used for ultrasonic surface rolling on aircraft engine blades, then the equipment structure is simple, but the manufacturing precision deteriorates due to blade flutter and deformation caused by high-amplitude and high-frequency ultrasonic vibration
Solution Approach 1:
The patent introduces a dynamic support system that can adaptively follow the blade surface during ultrasonic surface rolling. The support head is equipped with sensors to detect blade position and deformation in real-time, and the system dynamically adjusts support force and position to compensate for blade flutter and deformation, thereby maintaining manufacturing precision while using relatively simple equipment structure
Solution Approach 2:
The patent implements a feedback control system where sensors detect the actual position and deformation of the blade during ultrasonic surface rolling, and this information is fed back to the control system. The control system then adjusts the support force and positioning in real-time to offset blade flutter and deformation, ensuring accurate surface modification
2Device complexity
If a conventional CNC machining method is used for ultrasonic surface rolling on aircraft engine blades, then the process is simple, but the manufacturing precision deteriorates due to geometric inaccuracy of strengthening
Solution Approach 1:
The patent employs a dynamic support system that adapts to the blade surface geometry during ultrasonic surface rolling. The support head continuously adjusts its position and force application to match the complex curved surface of the blade, ensuring uniform force distribution and geometric accuracy of strengthening even on complex shapes
Solution Approach 2:
The patent dynamically adjusts multiple process parameters including support force magnitude, support position, and ultrasonic vibration amplitude during the surface rolling process. These parameter changes are made in real-time based on blade position and surface geometry to maintain geometric accuracy of strengthening throughout the complex blade contour
3Manufacturing precision
If a robot with high degrees of freedom is used to machine complex curved workpieces, then the accessibility and accuracy are improved, but the device complexity increases
Solution Approach 1:
The patent employs a multi-functional robot system that integrates positioning, support, and ultrasonic surface rolling capabilities. The robot end effector combines multiple functions including precise positioning of the ultrasonic tool, application of support force, and coordination with the CNC system, thereby achieving high machining accuracy on complex curved blades while managing system complexity through functional integration
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
The system achieves accurate ultrasonic surface rolling on aircraft engine blades, reducing surface roughness, increasing hardness, and introducing beneficial residual compressive stress, thereby prolonging the service life of the blades.
Implementation Method 1
Through ultrasonic-assisted vibration, a spherical tool head hits a metal surface at a high frequency and a high amplitude, so that a plastic deformation layer is produced on the machined surface
Implementation Method 2
a spherical tool head hits a metal surface at a high frequency and a high amplitude, so that a plastic deformation layer is produced on the machined surface
Implementation Method 3
a beneficial residual compressive stress is introduced into the material, finally achieving the purpose of prolonging the service life of the material
Data Source
AI summary
The application relates to a robot machining system and control method for ultrasonic surface rolling process of an aircraft engine blade. The robot machining system includes: a robot, to which an ultrasonic surface rolling process device is fixed, the robot drives the ultrasonic surface rolling process device to move; a base provided with a spindle turntable and a three-dimensional mobile lifting device, the spindle turntable being provided with a rotatable blade clamp, and a flexible follow-up support head being fixed to the three-dimensional mobile lifting device; and a control system, which is in electrical connection or communication connection with the robot, the spindle turntable and the three-dimensional mobile lifting device, respectively. According to the application, the robot assists in clamping ultrasonic rolling device and cooperates with the three-dimensional mobile lifting device and the flexible follow-up support head, such that the accurate ultrasonic surface rolling process of blade is realized.