Multi-objective Planning of Interference-free Machining Postures for Robotic Grinding of Components with Narrow Processing Channel

doi:10.3901/JME.260432

Abstract

Abstract: The processing channels of integral components such as blisk, integral impeller, and closed impeller of aero-engine are twisted, narrow, and deep, and are prone to various machining interference, which are typical difficult-to-machine components. To improve their machined surface quality, the robotic belt grinding process that is widely used as the last finishing process of the integral component is taken as the research object, and a multi-objective planning method of interference-free machining postures for robotic belt grinding of integral components is presented. With this method, a definition of interference-free robot configuration space (IFRC-Space) is first proposed. Next, an exploration experiment on the evolution law of IFRC-Space along the toolpath when grinding integral components is carried out, which concluded that IFRC-Space varies continuously along the toolpath. Based on the conclusion, a rapid computation method of IFRC-Space is proposed by using the edge detection operator of images. Then, a multi-objective optimization algorithm of grinding postures is advanced based on IFRC-Space. With the algorithm, the indicators including interference avoidance, singularity avoidance, smoothness of grinding postures, and the kinematic performance of the robot can be comprehensively considered, which enables the automatic generation and multi-objective optimization of the interference-free machining postures for robotic belt grinding of integral components. The effectiveness and practicability of the proposed method are verified by toolpath planning experiments for robotic belt grinding of aero-engine blisk and closed impeller.

Key words: integral components, robotic, belt grinding, toolpath planning, interference avoidance

CLC Number:

TH164

XIE Hailong, YIN Juhong, WANG Qinghui, ZHAO Chongguang, LIAO Zhaoyang. Multi-objective Planning of Interference-free Machining Postures for Robotic Grinding of Components with Narrow Processing Channel[J]. Journal of Mechanical Engineering, 2026, 62(9): 408-419.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260432

http://www.cjmenet.com.cn/EN/Y2026/V62/I9/408

References

[1] 黄云，肖贵坚，邹莱. 整体叶盘抛光技术的研究现状及发展趋势[J]. 航空学报，2016，37(7)：2045-2064. HUANG Yun，XIAO Guijian，ZOU Lai. Current situation and development trend of polishing technology for blisk[J]. Acta Aeronautica et Astronautica Sinica，2016，37(7)：2045-2064.
[2] ZHU Wule，BEAUCAMP A. Compliant grinding and polishing：A review[J]. International Journal of Machine Tools and Manufacture，2020，158：103634.
[3] ZHU Dahu，FENG Xiaozhi，XU Xiaohu，et al. Robotic grinding of complex components：A step towards efficient and intelligent machining – challenges，solutions，and applications[J]. Robotics and Computer-Integrated Manufacturing，2020，65：101908.
[4] LV Yuanjian，PENG Zhen，QU Chao，et al. An adaptive trajectory planning algorithm for robotic belt grinding of blade leading and trailing edges based on material removal profile model[J]. Robotics and Computer-Integrated Manufacturing，2020，66：101987.
[5] MU Yilin，LV Chong，LI Heng，et al. A novel toolpath for 7-NC grinding of blades with force-position matching[J]. The International Journal of Advanced Manufacturing Technology，2022，123(1)：259-270.
[6] MA Kaiwei，HAN Liang，SUN Xiaoxiao，et al. A path planning method of robotic belt grinding for workpieces with complex surfaces[J]. IEEE/ASME Transactions on Mechatronics，2020，25(2)：728-238.
[7] YANG Jianhua，ZHANG Dinghua，WU Baohai，et al. A path planning method for error region grinding of aero-engine blades with free-form surface[J]. The International Journal of Advanced Manufacturing Technology，2015，81(1)：717-728.
[8] 黄云，肖贵坚，邹莱. 航空发动机叶片机器人精密砂带磨削研究现状及发展趋势[J]. 航空学报，2019，40(3)：53-72. HUANG Yun，XIAO Guijian，ZOU Lai. Current situation and development trend of robot precise belt grinding for aero-engine blade[J]. Acta Aeronautica et Astronautica Sinica，2019，40(3)：53-72.
[9] XIAO Guijian，CHEN Shulin，SONG Kangkang，et al. A novel trajectory planning method based on reverse compensation of profile error for robotic belt grinding of blisk[J]. Journal of Manufacturing Processes，2022，84：508-521.
[10] 闫守鑫，王伟，苏鹏飞，等. 大型复杂锻件打磨路径的智能化规划方法[J]. 机械工程学报，2024，60(11)：216-225. YAN Shouxin，WANG Wei，SU Pengfei，et al. Intelligent path planning method for grinding large complex forging parts[J]. Journal of Mechanical Engineering，2024，60(11)：216-225.
[11] LU Yaoan，TANG Kai，WANG Chengyong. Collision-free and smooth joint motion planning for six-axis industrial robots by redundancy optimization[J]. Robotics and Computer-Integrated Manufacturing，2021，68：102091.
[12] HUANG Zhi，SONG Rui，WAN Congbao，et al. Trajectory planning of abrasive belt grinding for aero-engine blade profile[J]. The International Journal of Advanced Manufacturing Technology，2019，102(1)：605-614.
[13] XIAO Guijian，HUANG Yun，WANG Jie. Path planning method for longitudinal micromarks on blisk root-fillet with belt grinding[J]. The International Journal of Advanced Manufacturing Technology，2018，95(1)：797-810.
[14] LV Chong，ZOU Lai，HUANG Yun，et al. A novel toolpath for robotic adaptive grinding of extremely thin blade edge based on dwell time model[J]. IEEE/ASME Transactions on Mechatronics，2022，27(6)：4429-4439.
[15] XIE Hailong，LI Jingrong，LIAO Zhaoyang，et al. A robotic belt grinding approach based on easy-to-grind region partitioning[J]. Journal of Manufacturing Processes，2020，56：830-844.
[16] XIE Hailong，WANG Qinghui，ONG S K，et al. Automatic generation of interference-free and posture-smooth toolpath for robotic belt grinding of complex workpieces[J]. IEEE/ASME Transactions on Mechatronics，2023，28(1)：518-530.
[17] XIE Hailong，WANG Qinghui，ONG S K，et al. Adaptive human-robot collaboration for robotic grinding of complex workpieces[J]. CIRP Annals，2022，71(1)：285-288.
[18] 罗来臻，赵欢，王辉，等. 复杂曲面机器人磨抛位姿优化与刀路规划[J]. 机械工程学报，2022，58(3)：284-294. LUO Laizhen，ZHAO Huan，WANG Hui，et al. Pose optimization and tool path planning for robotic grinding of complicated curved surface[J]. Journal of Mechanical Engineering，2022，58(3)：284-294.
[19] HASHEMIAN A，BO P，BARTOŇ M. Reparameterization of ruled surfaces：Toward generating smooth jerk-minimized toolpaths for multi-axis flank CNC milling[J]. Computer-Aided Design，2020，127：102868.
[20] MA Jianwei，HU Guoqing，QIN Fengze，et al. Global tool axis vector optimization based on the minimum angular acceleration of rotary axes[J]. The International Journal of Advanced Manufacturing Technology，2020，107(5)：2121-2136.
[21] XIAO Qunbao，WAN Min，ZHANG Weihong，et al. Tool orientation optimization for the five-axis CNC machining to constrain the contour errors without interference[J]. Journal of Manufacturing Processes，2022，76：46-56.
[22] XU Jinting，ZHANG Dayuan，SUN Yuwen. Kinematics performance oriented smoothing method to plan tool orientations for 5-axis ball-end CNC machining[J]. International Journal of Mechanical Sciences，2019，157-158：293-303.
[23] WANG Yingpeng，XU Jinting，SUN Yuwen. Tool orientation adjustment for improving the kinematics performance of 5-axis ball-end machining via CPM method[J]. Robotics and Computer-Integrated Manufacturing，2021，68：102070.
[24] XIE Hailong，WANG Qinghui，LIAO Zhaoyang，et al. A rapid approach of computing multi-axis tool accessible space for general cutter model by utilizing programmable graphics pipeline[J]. IEEE/ASME Transactions on Mechatronics，2022，27(5)：3373-3384.
[25] GONZALEZ C I，MELIN P，CASTRO JR，et al. An improved sobel edge detection method based on generalized type-2 fuzzy logic[J]. Soft Computing，2016，20(2)：773-784.
[26] ZARGARBASHI S H H，KHAN W，ANGELES J. The Jacobian condition number as a dexterity index in 6R machining robots[J]. Robotics and Computer-Integrated Manufacturing，2012，28(6)：694-699.
[27] EZAIR B，ELBER G. Automatic generation of globally assured collision free orientations for 5-axis ball-end tool-paths[J]. Computer-Aided Design，2018，102：171-181.