Toolpath generation for finishing machining of blades based on geometric features

doi:10.11996/JG.j.2095-302X.2026020402

Abstract

Abstract:

As a core component in aerospace manufacturing, aero-engine blades face challenges of significant cutting-force fluctuations and severe tool wear during finishing due to their complex geometries and high precision requirements. To achieve stable cutting-force control in complex-surface machining, a toolpath-planning method integrating blade geometric-feature analysis and cutting-parameter optimization was proposed. First, a cutting-force model based on micro-element cutting theory was developed to analyze the relationship among surface features, cutting parameters, and cutting forces. Subsequently, to address force fluctuations caused by fixed parameters in traditional paths, a variable-scale chaotic algorithm was used co-optimize tool-axis inclination, feed rate, and cutting depth, establishing an optimization model to minimize force fluctuation. Finally, step length and row spacing were calculated based on blade geometry, and the isoparametric-line method plans tool-contact-point trajectories. Optimal cutting parameters for each point were determined by integrating the force model with the optimization results, generating the complete finishing toolpath. Results showed that this method optimized cutting-force distribution, achieved smooth machining forces, reduced tool fatigue and wear, and extended tool life. This work provided a new force-control-based approach for precision machining of complex surfaces.

Key words: blade geometric features, tool path generation, cutting-force calculation, cutting-parameter optimization, chaotic optimization

CLC Number:

TG547
V263

TU Yihao, MA Wenyang, YAN Guangrong. Toolpath generation for finishing machining of blades based on geometric features[J]. Journal of Graphics, 2026, 47(2): 402-410.

Figures/Tables 16

Fig. 1 Ball-end milling cutter model

Fig. 2 Cutting edge analysis of ball-end milling cutter

Fig. 3 Cutting edge micro-element force analysis

Fig. 4 Tool-workpiece engagement zone integration limit calculation process

Fig. 5 Variable-scale chaotic optimization process

Fig. 6 Comparison of cutting forces before and after optimization ((a) Before optimization; (b) After optimization)

Table 1 Analysis of cutting parameter optimization results

参数	优化前/N	优化后/N	改善幅度/%
平均值	57.358 0	57.700 2	+0.6
标准差	11.50	0.03	-99.7
最大值	80.642 0	57.756 0	-28.3
最小值	38.124 1	57.619 4	+51.2

Table 2 Surface curvature characteristic analysis

高斯曲率	平均曲率
高斯曲率	H>0	H=0	H<0
K>0	凹椭圆点		凸椭圆点
K=0	凹抛物点	平面	凸抛物点
K<0	双曲点	双曲点	双曲点

Fig. 7 Blade surface convexity-concavity analysis ((a) Pressure-side (concave) surface characterization; (b) Suction-side (convex) surface characterization)

Fig. 8 Pressure-side surface curvature analysis and stepover calculation

Fig. 9 Pressure-side surface stepover planning

Table 3 Toolpath curvature interval partitioning and step length selection

主曲率区间	走刀步长	特点
(0，0.000 2)	5.0	平坦区域，大走刀步长
(0.000 2，0.001 0)	2.5	轻微弯曲，适中步长
(0.001 0，0.002 0)	1.2	中等弯曲，较小步长
(0.002 0，∞)	0.6	较陡弯曲，精细步长

Fig. 10 Curvature interval partitioning for a single toolpath on pressure-side surface

Fig. 11 Comparison of cutting forces before and after toolpath optimization

Fig. 12 Optimized cutting parameter values for the toolpath

Fig. 13 Blade surface cutter contact point trajectory planning ((a) Pressure-side surface; (b) Suction-side surface)

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