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A robotic polishing trajectory planning method for TBCs of aero-engine turbine blade using measured point cloud

点云 弹道 抛光 表面粗糙度 计算机科学 点(几何) 涡轮叶片 曲率 材料科学 模拟 机械工程 涡轮机 工程类 计算机视觉 几何学 数学 复合材料 物理 天文
作者
Xufeng Liang,Zhenhua Cai,Chunnian Zeng,Zixin Mu,Zifan Li,Fan Yang,Tingyang Chen,Shujuan Dong,Chunming Deng,Shaopeng Niu
出处
期刊:Industrial Robot-an International Journal [Emerald Publishing Limited]
卷期号:50 (2): 275-286 被引量:10
标识
DOI:10.1108/ir-05-2022-0141
摘要

Purpose The application of thermal barrier coatings (TBCs) allows aero-engine blades to operate at higher temperatures with higher efficiency. The preparation of the TBCs increases the surface roughness of the blade, which impacts the thermal cycle life and thermal insulation performance of the coating. To reduce the surface roughness of blades, particularly the blades with small size and complex curvature, this paper aims to propose a method for industrial robot polishing trajectory planning based on on-site measuring point cloud. Design/methodology/approach The authors propose an integrated robotic polishing trajectory planning method using point cloud processing technical. At first, the acquired point cloud is preprocessed, which includes filtering and plane segmentation algorithm, to extract the blade body point cloud. Then, the point cloud slicing algorithm and the intersection method are used to create a preliminary contact point set. Finally, the Douglas–Peucker algorithm and pose frame estimation are applied to extract the tool-tip positions and optimize the tool contact posture, respectively. The resultant trajectory is evaluated by simulation and experiment implementation. Findings The target points of trajectory are not evenly distributed on the blade surface but rather fluctuate with surface curvature. The simulated linear and orientation speeds of the robot end could be relatively steady over 98% of the total time within 20% reduction of the rest time. After polishing experiments, the coating roughness on the blade surface is reduced dramatically from Ra 7–8 µm to below Ra 1.0 µm. The removal of the TBCs is less than 100 mg, which is significantly less than the weight of the prepared coatings. The blade surface becomes smoothed to a mirror-like state. Originality/value The research on robotic polishing of aero-engine turbine blade TBCs is worthwhile. The real-time trajectory planning based on measuring point cloud can address the problem that there is no standard computer-aided drawing model and the geometry and size of the workpiece to be processed differ. The extraction and optimization of tool contact points based on point cloud features can enhance the smoothness of the robot movement, stability of the polishing speed and performance of the blade surface after polishing.
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