Two-sided ultrasonic surface rolling process of aeroengine blades based on on-machine noncontact measurement

Abstract

As crucial parts of an aeroengine, blades are vulnerable to damage from long-term operation in harsh environments. The ultrasonic surface rolling process (USRP) is a novel surface treatment technique that can highly improve the mechanical behavior of blades. During secondary machining, the nominal blade model cannot be used for secondary machining path generation due to the deviation between the actual and nominal blades. The clamping error of the blade also affects the precision of secondary machining. This study presents a two-sided USRP (TS-USRP) machining for aeroengine blades on the basis of on-machine noncontact measurement. First, a TS-USRP machining system for blade is developed. Second, a 3D scanning system is used to obtain the point cloud of the blade, and a series of point cloud processing steps is performed. A local point cloud automatic extraction algorithm is introduced to extract the point cloud of the strengthened region of the blade. Then, the tool path is designed on the basis of the extracted point cloud. Finally, an experiment is conducted on an actual blade, with results showing that the proposed method is effective and efficient.

Keywords

aeroengine blades / on-machine noncontact measurement / point cloud processing / path planning / surface strengthening

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Acknowledgements

The authors gratefully acknowledge the financial support extended by the National Natural Science Foundation of China (Grant Nos. 51975214, 51725503, and 51575183) and the 111 Project. Zhang X C is also grateful for the support by the Major Program of the National Natural Science Foundation of Shanghai (Grant No. 2019-01-07-00-02-E00068).

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