Flexible fixture designs and accuracy improvements for the adaptive machining of near-net-shaped blades

Abstract

The machining accuracy of the blade, which serves as a vital component of the aero-engine, exerts a direct influence on the engine's performance. The near-net-shaped blade, characterized by its precision, reliability, and economic efficiency, holds substantial significance for both the academic and industrial realms. This paper summarizes the state-of-the-art developments in flexible fixture design and adaptive machining of near-net-shaped blades, with the objective of conducting a comprehensive analysis of current research studies and offering valuable insights to enhance the future machining accuracy of near-net-shaped blades. Firstly, the design of flexible fixture and adaptive machining are reviewed. Adaptive machining technology based on on-machine measurement is a key technology that has emerged in recent years to achieve high-precision machining of aircraft engine blades. Subsequently, a detailed examination is conducted into the mechanisms underlying error formation during the blade machining process, with particular focus on the blade's thin-walled structure and low-stiffness characteristics. Both single-process and multi-process machining errors are discussed. Furthermore, an extensive review of adaptive error control strategies applied in near-net-shaped blade machining is presented, with emphasis on model registration algorithms, machining model reconstruction, and part deformation modeling. Finally, the key contributions and limitations of existing research are summarized, and prospects for future research directions are outlined.