基于叶片几何特征的精加工刀具轨迹生成

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.