Flexible stratification method based on constant cutting force for machining blade surfaces

During milling of free-form surfaces, cutting force varies due to the variation of workpiece surface curvature, which can seriously affect machining quality. In this study, a layered strategy was proposed for flexible machining of complex parts with variable curvatures. By taking a blade as the research object, we first considered a constant cutting force as the starting point. The relationship between the machining allowance and the radius of curvature of the workpiece under a certain cutting force was established. By analyzing the curvature of each position of the blade, a reasonable cutting allowance was set for each layer and the machining process was carried out layer by layer, such that a stable cutting force was maintained on the workpiece surface during machining of each layer. Second, the blade surface deformation law was determined by using the T-spline surface characteristics and an improved offset algorithm, and a series of deformation surfaces was obtained. Finally, the feasibility of the proposed method was verified by using finite element simulations and validated by experiment, and the advantages of the proposed method were verified by comparison with the existing main blade processing methods.