Performance-oriented layout optimization of a multi-spindle drilling cell for acoustic liners in aero-engine nacelles

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes Pub Date : 2025-07-08 DOI:10.1016/j.jmapro.2025.06.107

Haoyu Tian , Biao Mei , Yun Fu , Yongtai Yang , Weidong Zhu

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引用次数: 0

Abstract

Laying acoustic liners is one of the most effective ways to reduce aero-engine noise. Traditional single-spindle drilling systems are inadequate for high-quality and efficient drilling for large-scale sound-absorbing holes on acoustic liners. Therefore, this paper develops a robotic multi-spindle drilling cell (RMDCell) that integrates a multi-spindle drilling end-effector, a standard industrial robot, and a rotatable clamping fixture. A robot performance-oriented layout optimization method is studied for the RMDCell to improve the drilling quality of acoustic liners in aero-engine nacelles. Firstly, a weighted comprehensive performance model of the multi-spindle drilling robot is built, integrating joint limit avoidance, singularity avoidance, and robot stiffness performances. Thereinto, a new robot stiffness performance index is introduced, and a variable robot stiffness weight is derived considering the end-effector's spindle configuration. Secondly, a dimensionality reduction method of layout optimization parameters and a drilling zone division method are proposed for the RMDCell of nacelle acoustic liners. A bi-level optimization algorithm for RMDCell layout parameters is developed. The algorithm fuses particle swarm optimization (PSO) and deep hierarchical feature learning on point sets in a metric space (PointNet++). Finally, drilling experiments are conducted based on the developed RMDCell. The results show that the comprehensive robot performance index is reduced by 39.8 % after optimization compared to the comprehensive robot performance before layout optimization. The layout optimization method effectively reduces defects such as burrs, delamination, and tearing in composite sound-absorbing holes. The average delamination factor decreases by 16.5 %. The robot performance-oriented layout optimization significantly improves the drilling quality, which meets the manufacturing quality requirements of the acoustic liner of an aero-engine nacelle.

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航空发动机机舱声学衬套多轴钻进单元的性能优化设计

铺设声学衬垫是降低航空发动机噪声的最有效方法之一。传统的单轴钻孔系统无法满足在声学衬垫上高质量、高效地钻取大型吸声孔的要求。因此，本文开发了一种机器人多轴钻孔单元（RMDCell），该单元集成了多轴钻孔末端执行器、标准工业机器人和可旋转夹紧夹具。研究了一种面向机器人性能的RMDCell布局优化方法，以提高航空发动机短舱内声学衬垫的钻进质量。首先，综合关节极限规避、奇异规避和机器人刚度性能，建立了多轴钻孔机器人的加权综合性能模型；在此基础上，引入了一种新的机器人刚度性能指标，推导了考虑末端执行器主轴结构的可变机器人刚度权重。其次，针对短舱声衬套RMDCell，提出了布置优化参数降维方法和钻井区域划分方法；提出了一种RMDCell布局参数的双层优化算法。该算法融合了粒子群算法（PSO）和深度层次特征学习算法（PointNet++）。最后，基于开发的RMDCell进行了钻井实验。结果表明，优化后的机器人综合性能指标比布局优化前的机器人综合性能降低了39.8%。该布局优化方法有效地减少了复合材料吸声孔中的毛刺、分层、撕裂等缺陷。平均分层系数降低了16.5%。以性能为导向的机器人布局优化显著提高了钻孔质量，满足某型航空发动机短舱声学衬垫的制造质量要求。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-

CiteScore

10.20

自引率

11.30%

发文量

833

审稿时长

50 days

期刊介绍： The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.