Active and passive compliant force control of ultrasonic surface rolling process on a curved surface

Ultrasonic surface rolling process (USRP) is one of the effective mechanical surface enhancement techniques. During the USRP, unstable static force will easily do harm to the surface quality. In order to achieve a higher surface quality on the part with a curved surface, an active and passive compliant USRP system has been developed. The compliant USRP tool can produce the natural obedience deformation along the part surface. Force control based on the fuzzy Proportional-integral-derivative (PID) method is then designed to maintain the static force during the USRP. Experiments have been performed on a real aero-engine blade with curved surface. It is proved that the deigned active and passive compliant USRP system can significantly reduce the force variation from 42.2 N to 4.2 N, and achieve a uniform surface quality after processing.