Tool position feasible area of torus tool in machining blade root transitional surfaces

The integral interference happens frequently when machining transitional surfaces using torus tool, the main reason is the lack of the research on the tool position feasible area of complex torus tool in complex surface machining. Although the conventional optimization method may be competent in searching feasible tool position in large area, it is time-consuming. In order to avoid the interference between tool and transitional surface and improve the machining efficiency at the same time, a tool position optimization algorithm that is more suitable for the structure feature of this area is researched, so that the transitional surface can be strip-width maximization machined integrally without interference. Through the research on the feasible tool position of typical blade transitional surface, it is found that the shape of feasible area of tool position is scutellate, and the tool positions with the maximum machining strip width are located on the two bottom boundaries of the scutellate area, sometimes located on the endpoints of the boundaries. According to this principle, an optimal tool position searching method is proposed-searching along the bottom boundaries of the scutellate area, and optimizing the application of feasible area to obtain high machining efficiency. A certain aero-engine blade is taken as an example for calculation of tool position optimization and simulation and machining experiment to verify the validity of this method in machining the transitional surfaces of blade root area.