New planning algorithm of tool path for long turbine blades machining with twin-cutters

In order to solve the deformation problem during the manufacturing process of the long turbine blades, a tool path planning algorithm of the twin-cutters was proposed based on two optimization strategies, i.e., minimization of the radial cutting resultant force and minimization of the cutting resultant moment. An analytic cutting force model of the bullnose cutter was presented to predict the cutting force value of a single cutter. The cutting locations and cutters' orientation were then calculated in order to satisfy the two optimization strategies. The results show that with certain milling parameters, the tool path planning with the two optimization strategies can help to reduce the blade's process deformation by 31% and 55%, respectively. The optimized tool path can effectively compensate the cutting force and eventually reduce the blades' manufacturing deformation.