Optimal Tool Orientation Planning for Five-axis Machining of Open Blisk

This paper deals with optimization of five-axis tool orientations in the context of five-axis machining of open blisk. The purpose is to generate smooth tool orientations that leading to consistent surface quality which can respect the mechanical and aerodynamic properties of the aero-engine blisk. With this as the object, optimal tool orientation planning methods for five-axis machining of blisk are studied in this paper. Machining processes and tool path generation methods are first presented according to the structural characteristics of the blisk. Then the feasible region of tool orientation for planned CC point is determined by partitioning the unit sphere formed by all possible tool axis vectors and interference checking. Based on the simplified feasible region, constrained optimization method is used to get optimal tool orientations along the tool path. Finally, the presented methods are validated to show its effectiveness by planning tool orientations for the blade surface and hub surface of the blisk.