叶片双面砂带磨削工艺理论与关键技术研究
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摘要
随着我国科技发展，航空航天等高精尖领域对动力装置性能要求甚严。作为能源转换装置核心部件的叶片，其生产效率和加工精度对整机性能都有着重要的影响。目前叶片成型加工已经实现自动化，但是叶片磨削加工工序仍依赖手工，手工磨削叶片效率较低且叶片型面质量完全依赖操作者。近年来砂带磨削作为高效加工技术被应用到叶片精密加工中。
本文从砂带磨削工艺理论、叶片砂带磨削去除模型、叶片双面砂带磨削机床结构和机床整机模态分析等几方面开展了研究工作。
研究了砂带磨削工艺理论，获得了工艺参数对加工效率、磨削力和磨削温度的影响规律；提出了一种简便计算平面磨削力的经验公式，该经验公式考虑了磨削过程中工件与磨粒之间摩擦系的数变化对磨削力的影响。
测量叶片表面点云数据，通过逆向工程软件对点云数据进行处理工作，得到叶片三维实体模型。利用离散化网格面片，结合概率论、弹性力学以及接触力学等理论建立了叶片磨削去除模型。
为提高叶片砂带磨削效率，改善操作者工作环境，本文开发了一种新型叶片双面砂带磨削机床。利用双X轴和双Z轴的同步运动实现叶片双侧型面同步加工。砂带磨削系统采用了接触轮转换机构，该机构含有四个不同直径接触轮，以适应不同曲率叶片型面砂带磨削加工。利用激光干涉仪对机床的X轴以及Z轴进行了重复定位误差测量，测量结果表明误差均能满足加工需要。
基于弹性接触理论，对进给系统轴向接触刚度进行了研究，揭示了进给系统轴向接触刚度和轴向变形随载荷的变化规律。采用基于重复误差补偿的PID控制方法对进给伺服系统进行控制，并与传统PID控制结果进行了对比分析，结果表明本文提出的控制方法对机床进给伺服系统的控制精度优于传统PID。
利用有限元分析软件以及模态分析系统对叶片双面磨削机床模态进行了仿真和实验研究，实验结果表明有限元模型可以为改善机床性能提供依据。
The blade plays decisive role for the working performance of the wholemachine. The performance of the blade is related to the energy field, launch vehiclefields and national defense field. So the manufacturing efficiency, machiningaccuracy and surface roughness have important effect to the performance andefficiency of the energy conversion device. Some progress has been obtained inblade processing industry the past few years. There are special machines for thesurface of blades. The grinding process for the blade still depends on manualoperation. The grinding efficiency and the part accuracy are also very low in generalcase. Belt grinding has been used to the precision machining of blade as an efficientmachining technology. The research on the theory of belt grinding, the grindingremoval analysis based on discrete grid dough sheet, the structure and the controlmethod of the machine and the modal analysis of the machine are carried out in thispaper.
First, the research on the evaluation index of the performance of the belt grindingand the influencing factors of the belt grinding is carried out. The effect of grindingdepth, feed rate and the rotational speed of the tool on the grinding force is discussedin this paper. Then, an empirical formula to calculate the grinding force in surfacegrinding is proposed. The alterable friction coefficient in the grinding process isconsidered in the formula.
Data points of the blade are collected in this paper. Then the reverse engineeringsoftware is used to deal with the data points. The data points are repaired and thethree-dimensional solid model of the blade is built up.
The knowledge of probability theory, elasticity and contact mechanics is used tostudy the research on grinding removal depth based on the discrete grid dough sheet.
A new machine for grinding both sides of blade synchronically is proposed inthis paper to improve the efficiency. The four axes coordinated would be used to cut machining time in the synchronous machining region. The converted mechanism formultiple contact wheels is also developed to fit the blade surface with different radiusof curvature.
Laser measurement system is used to measure the repetitive position error ofX-orient and Z orient. The measure results show that the errors are in the allowedrange.
The axial contact stiffness of the feed system is studied based on the elasticcontact theory. Then a control method based on repetitive compensation for the Xaxial transmission system of the double-side blade grinding machine is proposed inthis paper. The simulation results show that the PID controller based on the repetitivecompensation controller had good robustness and high accuracy.
Modal analysis is the key point to improve the system performance. The modalanalysis of the machine is studied used the finite element analysis software and themodal testing system. The results are helpful to improve the performance of themachine.
本文从砂带磨削工艺理论、叶片砂带磨削去除模型、叶片双面砂带磨削机床结构和机床整机模态分析等几方面开展了研究工作。
研究了砂带磨削工艺理论，获得了工艺参数对加工效率、磨削力和磨削温度的影响规律；提出了一种简便计算平面磨削力的经验公式，该经验公式考虑了磨削过程中工件与磨粒之间摩擦系的数变化对磨削力的影响。
测量叶片表面点云数据，通过逆向工程软件对点云数据进行处理工作，得到叶片三维实体模型。利用离散化网格面片，结合概率论、弹性力学以及接触力学等理论建立了叶片磨削去除模型。
为提高叶片砂带磨削效率，改善操作者工作环境，本文开发了一种新型叶片双面砂带磨削机床。利用双X轴和双Z轴的同步运动实现叶片双侧型面同步加工。砂带磨削系统采用了接触轮转换机构，该机构含有四个不同直径接触轮，以适应不同曲率叶片型面砂带磨削加工。利用激光干涉仪对机床的X轴以及Z轴进行了重复定位误差测量，测量结果表明误差均能满足加工需要。
基于弹性接触理论，对进给系统轴向接触刚度进行了研究，揭示了进给系统轴向接触刚度和轴向变形随载荷的变化规律。采用基于重复误差补偿的PID控制方法对进给伺服系统进行控制，并与传统PID控制结果进行了对比分析，结果表明本文提出的控制方法对机床进给伺服系统的控制精度优于传统PID。
利用有限元分析软件以及模态分析系统对叶片双面磨削机床模态进行了仿真和实验研究，实验结果表明有限元模型可以为改善机床性能提供依据。
The blade plays decisive role for the working performance of the wholemachine. The performance of the blade is related to the energy field, launch vehiclefields and national defense field. So the manufacturing efficiency, machiningaccuracy and surface roughness have important effect to the performance andefficiency of the energy conversion device. Some progress has been obtained inblade processing industry the past few years. There are special machines for thesurface of blades. The grinding process for the blade still depends on manualoperation. The grinding efficiency and the part accuracy are also very low in generalcase. Belt grinding has been used to the precision machining of blade as an efficientmachining technology. The research on the theory of belt grinding, the grindingremoval analysis based on discrete grid dough sheet, the structure and the controlmethod of the machine and the modal analysis of the machine are carried out in thispaper.
First, the research on the evaluation index of the performance of the belt grindingand the influencing factors of the belt grinding is carried out. The effect of grindingdepth, feed rate and the rotational speed of the tool on the grinding force is discussedin this paper. Then, an empirical formula to calculate the grinding force in surfacegrinding is proposed. The alterable friction coefficient in the grinding process isconsidered in the formula.
Data points of the blade are collected in this paper. Then the reverse engineeringsoftware is used to deal with the data points. The data points are repaired and thethree-dimensional solid model of the blade is built up.
The knowledge of probability theory, elasticity and contact mechanics is used tostudy the research on grinding removal depth based on the discrete grid dough sheet.
A new machine for grinding both sides of blade synchronically is proposed inthis paper to improve the efficiency. The four axes coordinated would be used to cut machining time in the synchronous machining region. The converted mechanism formultiple contact wheels is also developed to fit the blade surface with different radiusof curvature.
Laser measurement system is used to measure the repetitive position error ofX-orient and Z orient. The measure results show that the errors are in the allowedrange.
The axial contact stiffness of the feed system is studied based on the elasticcontact theory. Then a control method based on repetitive compensation for the Xaxial transmission system of the double-side blade grinding machine is proposed inthis paper. The simulation results show that the PID controller based on the repetitivecompensation controller had good robustness and high accuracy.
Modal analysis is the key point to improve the system performance. The modalanalysis of the machine is studied used the finite element analysis software and themodal testing system. The results are helpful to improve the performance of themachine.
引文
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