Research on the dynamic flexible support machining method for propeller blades

Currently, most propeller machining adopts single-sided machining, and its vibration and deformation seriously affect the machining accuracy. To reduce the machining vibration and deformation, a dynamic, flexible support machining method is proposed, i.e., while the tool is machining, the multi-point flexible support device supports the blade and counteracts the milling force to suppress the vibration and deformation. Due to the blade’s complex shape and the support device’s special structure, the blade is divided into different areas. A support motion trajectory combining symmetric and asymmetric motions is planned, and then, a set of post-processing systems is introduced. After obtaining the tool position points, the ergodic method solves the support points cyclically. Subsequently, the support points are interpolated, and the vectors are smoothed to get smooth and continuous support trajectories. Finally, the machining parameters are calculated, and the machining data applicable to the XYZ-3RPS hybrid machine are integrated. The feasibility of the proposed support trajectory and post-processing algorithm was ultimately demonstrated through practical machining experiments. Finally, comparative experiments between supported and unsupported were conducted, and the results showed that supported machining reduced blade deformation by 35% compared to unsupported machining.