Research on polishing trajectory planning method for leading/trailing edge based on polishing removal model of counter torus flexible tool

To address the challenge of collaborative optimization between material removal efficiency and surface consistency caused by non-uniform machining allowances in the polishing of aero-engine blade leading/trailing edges, this paper proposes a trajectory planning method based on a removal model and a counter torus flexible polishing tool. By defining the counter torus flexible tool, a material removal model incorporating parameters such as curvature radius and preload is established through Hertz contact theory and orthogonal experimental data. Based on this model, a tool positioning coordinate system is constructed, and the tool posture is optimized by adjusting the yaw angle and rake angle to establish a trajectory optimization model with the goal of minimizing the average absolute deviation of cutting depth. Experiments show that when machining simple and complex blades with the counter torus flexible tool, the number of tool paths required is 9.8 % and 23.1 % of that of conventional convex tools, respectively. The surface roughness is better than Ra 0.4 μm, and the uniformity of material removal depth at the leading/trailing edges is significantly improved. This method provides theoretical and technical support for high-precision and high-efficiency polishing of aero-engine blade leading/trailing edges.