Study on material removal and process optimization of composite material curved shell components robot grinding under flexible contact mode

Composite material curved shell components are key parts of the new generation of high-speed aircraft and missile systems; grinding quality of these components directly affects service performance of the equipment. Optimizing processing process parameters with material removal depth and surface roughness as quality targets is an effective means to improve grinding quality. In this paper, flexible grinding disc is used to process such curved components; for this grinding method under flexible contact mode, deformation of the grinding tool is associated with actual geometric surface shape of the components, then a method for analysing deformation in grinding contact area is proposed combined with the compression physical characteristics of grinding tool, material removal depth prediction model is established based on this method, and processing path interval is optimized with the goal of uniform material removal. Surface roughness prediction model is obtained by conducting experiments and regression analysis, which can be combined with the material removal depth prediction model to achieve grinding quality prediction. In order to meet the actual processing quality requirements of achieving the target range of roughness, reducing material removal depth and improving machining efficiency, a multi-objective optimization method based on grey correlation analysis is proposed. Verification experiment results show that research of this article effectively achieves prediction of grinding quality and improvement of removal uniformity, optimal process parameter combination can reach material removal depth of 21.4 μm and surface roughness Ra of 1.31 μm, improves processing efficiency by 38.2%, improving the comprehensive grinding quality.