Research on prediction and compensation strategy of milling deformation error of aitanium alloy integral blisk blade

Integral blisk blades are typical complex curved structures with small thickness, low stiffness, and complex boundaries. Due to the high material removal rate during the machining process, they are prone to force-induced deformation, resulting in significant machining errors. This seriously contradicts the requirements for high design accuracy and surface accuracy in the aerospace industry. Therefore, accurately predicting the distribution pattern of deformation caused by dynamic milling forces during the machining process and proposing reasonable error compensation strategies are urgent issues to be solved in the manufacturing of integral blisk blade. Firstly, this paper establishes a prediction model for the deformation distribution during the milling process of the integral blisk blade. Secondly, based on the finite element deformation prediction model of blades, the selection of blade milling processing methods and parameters was completed with the goal of minimizing machining deformation. Finally, a reverse reconstruction geometric modeling compensation strategy is proposed, and the tool path program containing the deformation error compensation amount is regenerated. The prediction model and compensation strategy proposed in this paper were validated through milling experiments and profile accuracy measurement experiments on a certain aeroengine integral blisk blade. The results showed that the prediction model has high reliability, with an average error of 7.96%; the new compensation strategy can reduce the tool-yielding error to within the tolerance range. This study will provide technical support for improving the machining accuracy and efficiency of integral blisk blade.