Research on machining error prediction of open blade under dynamic loading

The instantaneous cutting contact relationship between tool and workpiece is changing with the change of curvature profile of open blade impeller. This leads to a strong nonlinear characteristic of the dynamic cutting load change during the machining of this type of parts, which affects the machining accuracy of the blade. This paper proposes a method to predict the machining error of ball-end milling under dynamic load. This method considers the influence of the curvature change of blade profile. Based on the analysis of the instantaneous cutting contact of complex surface in ball-end milling, a prediction model of the instantaneous undeformed cutting thickness of ball-end milling under the influence of surface curvature changes is constructed. Based on this model, the correction of the prediction model of machining complex surface milling force is realized. The prediction of the machining error when the complex surface is thin-walled impeller is processed under dynamic load. Finally, the effectiveness and accuracy of the method are verified through ball-end milling experiments. The research can provide guidance for the control and compensation of milling machining errors of complex-shaped thin-walled open blade.