Error analysis of blade milling considering surface features and deformation

Abstract Thin-walled impeller blade curvature changes in the milling process, low stiffness and other reasons lead to large milling processing error, in order to compensate for online blade milling processing error,A milling machining error prediction method is proposed by considering the curved surface features and deformation of the blade. First, based on the tool-worker contact relationship of blade curvature and machining deformation individually, the undeformed and deformation chip thickness models considering curvature and deformation are constructed to analyze influence law of curvature change and deformation on the chip thickness individually; Then, change amount of the chip thickness considering undeformed and deformed in the tool coordinate system is converted to the surface coordinate system. The surface normal vector of variation is taken as the predicted machining error; Finally, corresponding experiments are conducted on five-axis machine to indicate that the error between the predicted and the experimentally measured machining error during stable milling falls within 21%.