Theoretical modeling and compensation analysis of blade machining deformation: Mechanism, principles and experimental validation

Thin-walled blades are critical components in high-end equipment such as aero-engines. Due to their complex geometric profiles and low structural stiffness, they are prone to deformation and contour errors during machining, which directly affect equipment performance and service life. To effectively control such errors, this paper proposes an integrated methodology framework for machining deformation control of thin-walled blades, covering the complete process of “error detection-compensation-verification.” This approach integrates theoretical analysis with experimental validation, systematically analyzing deformation mechanisms and considering the influence of milling force-induced plastic deformation and tool elastic displacement. Building on this analysis, this study proposes a hierarchical compensation strategy utilizing point cloud registration technology, which involves local error compensation followed by global deviation compensation. Experimental results show that the proposed method can significantly improve blade machining accuracy: the average deviation was reduced from −0.0085 to −0.0013 mm, and the standard deviation decreased from 0.032 to 0.010 mm. The findings indicate that this method exhibits certain feasibility and effectiveness in suppressing machining deformation of thin-walled blades, providing theoretical reference and practical guidance for deformation control of high-precision curved-surface components.