Research on Semi-active Suppression of Flutter in Robotic Grinding for Aero-engine Blades

doi:10.3901/JME.2025.05.228

Abstract

Abstract: In order to decrease the negative impact of chatter on the surface quality of blade-type thin-walled parts during robotic grinding machining, a semi-active control method to suppress the grinding chatter is proposed. Taking the robotic belt grinding processing system for aero-engine blades as the research object, a two-degree-of-freedom regenerative chatter model is established, and it is found that the blade stiffness has an important influence on the stability of the grinding system. Through the finite element analysis software for more in-depth analysis of the grinding system, it is feasible to use the auxiliary support to adjust the stiffness and damping of the grinding system to achieve chatter suppression. Therefore, a magnetic fluid damper is designed to control the stiffness and damping of the damper through the magnetic field, so as to reduce the chattering energy. Finally, the vibration signals of the blade grinding system and the surface roughness of the blade are obtained through the experiment. The research and analysis show that the peak amplitude of the blade grinding is reduced by 45% after the vibration reduction, and the surface roughness could reach 0.17μm. The semi-active control of the blade grinding system is realized, and the machining quality of the blade surface is significantly improved.

Key words: robot machining, dynamic modeling, chatter suppression, magnetic fluid damper, regenerative chatter

CLC Number:

TG156

QI Ruolong, WANG Jie, LI Lun, ZHAO Jibin. Research on Semi-active Suppression of Flutter in Robotic Grinding for Aero-engine Blades[J]. Journal of Mechanical Engineering, 2025, 61(5): 228-238.

References

[1] 朱子俊，朱祥龙，董志刚，等. 磨削加工颤振稳定性研究综述[J]. 机械工程学报，2023，59(21)：15-33. VZHU Zijun，ZHU Xianglong，DONG Zhigang，et al. Review of research on flutter stability in grinding process[J]. Journal of Mechanical Engineering，2023， 59(21)：15-33.
[2] 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. Research status and development trend of aero-engine blade robot precision belt grinding[J]. Acta Aeronautica et Astronautica Sinica，2019，40(3)：53-72.
[3] HU L，LI Y，CHEN Y. Research on machining technology of high speed and ultra-thin wall parts[J]. Journal of Mechanical Science and Technology，2020，34：4621-4629.
[4] 王志学，刘献礼，李茂月，等. 考虑力致变形影响的薄壁件铣削多点接触稳定性预测[J]. 机械工程学报，2022，58(17)：309-320. WANG Zhixue，LIU Xianli，LI Maoyue，et al. Multi-point contact stability prediction considering force-induced deformation effect in milling thin-walled parts[J]. Chinese Journal of Mechanical Engineering，2022，58(17)： 309-320.
[5] 黎先才，叶欢，何志强. 航空发动机中小型整体叶盘自动化抛光技术[J]. 组合机床与自动化加工技术， 2021，11：143-146. LI Xiancai，YE Huan，HE Zhiqiang. Automatic polishing technology of small and medium-sized monolithic blade disc for aeroengine[J]. Combined Machine Tool and Automatic Processing Technology，2021，11：143-146.
[6] 王战玺，张晓宇，李飞飞，等. 机器人加工系统及其切削颤振问题研究进展[J]. 振动与冲击，2017，36(14)：147-155. WANG Zhanxi，ZHANG Xiaoyu，LI Feifei，et al. Review on the research development of robot machining system and its cutting chatter problem[J]. Journal of Vibration and Shock，2017，36(14)：147-155.
[7] HAZEL B，RAFIEIAN F，LIU Z. Impact-cuttingand regenerative chatter in robotic grinding[C]//American Society of Mechanical Engineers. International Mechanical Engineering Congress and Exposition，November 11-17, 2011，Denver，Colorado. ASME，2011：349-359.
[8] BARJAŠIĆ D，STEGIĆ M，JURAN M. Numerical evaluation of plane grinding stability[J]. Transactions of FAMENA，2023，47(1)：13-20.
[9] 金华. 整体叶盘砂带磨削加工振动及工艺优化数值仿真研究[D]. 重庆：重庆大学，2017. JIN Hua. Numerical simulation study on vibration and process optimization of monolithic disc abrasive belt grinding[D]. Chongqing：Chongqing University， 2017.
[10] 迟玉伦，李郝林. 切入式外圆磨削接触刚度与固有频率研究[J]. 中国机械工程，2016，27(10)：1294-1298. CHI Yulun，LI Haolin. Research on contact stiffness and natural frequency of in-cut cylindrical grinding[J]. China Mechanical Engineering，2016，27(10)：1294-1298.
[11] SILVA M M，VENTER G S，VAROTO P S，et al. Experimental results on chatter reduction in turning through embedded piezoelectric material and passive shunt circuits[J]. Mechatronics，2015，29：78-85.
[12] 梅科. 整体叶盘砂带磨削加工颤振抑制及末端接触力控功能模块优化[D]. 重庆：重庆大学，2019. MEI Ke. Optimization of flutter suppression and end contact force control function module in monolithic disc abrasive belt grinding[D]. Chongqing：Chongqing University，2019.
[13] YAO J，CHANG J，LI D，et al. The dynamics analysis of a ferrofluid shock absorber[J]. Journal of Magnetism and Magnetic Materials，2016，402：28-33.
[14] LI Y，LI D，LI Y. Performance tests and design of a series of magnetic fluid shock absorbers with varying stiffness based on optimal stiffness formula[J]. Frontiers in Materials，2022，1011550：1-11.
[15] YANG C，FU J，YU M，et al. A new magnetorheological elastomer isolator in shear–compression mixed mode[J]. Journal of Intelligent Material Systems and Structures， 2015，26(10)：1290-1300.