A Novel Toolpath for Robotic Adaptive Grinding of Extremely Thin Blade Edge Based on Dwell Time Model

High precision and high efficiency in robotic grinding of aero-engine extremely thin blade edges is a challenging problem. In this article, a novel toolpath planning method is proposed based on the derived dwell time calculation model and the developed interpolation algorithm. The dwell time of each cutter contact point is solved based on the matrix method by consideration of the revised material removal model and machining allowance distribution. To optimize the previous interpolation algorithm based on geometric intersection, an arc length and Taylor binary expansion optimization are proposed to plan cutter contact points according to the dwell time and the curvature changes of blade edges. Subsequently, the tool orientation is corrected based on a double-vector controlling method to avoid the processing interference. Simulation results show that the proposed interpolation algorithm has improved the path coverage by 17.6%, and its computational efficiency is 34 times higher than that in previous algorithm. The comparative robotic grinding experiment results show that the proposed toolpath has improved the surface profile accuracy of blade edge to 0.042 mm, and its machining accuracy is 14.3–46.2% higher than that of other methods.