A review of 5-axis milling techniques for centrifugal impellers: Tool-path generation and deformation control

Abstract

Centrifugal impellers (CIs) boast advantages such as compact structure, lightweight characteristics, and high single-stage pressure ratio. These benefits make them essential across sectors such as aerospace, energy and power, and automotive. The manufacturing process of impellers plays a crucial role in determining their aerodynamic performance and production costs. It demands attention to diverse processing methods, the distinctive features of free-form surface and thin-walled blades, and factors affecting manufacturing accuracy and efficiency. Consequently, the manufacturing technologies for impeller machining have become the focal point of current research. The 5-axis milling manufacturing process for CIs has been extensively analyzed and reviewed. This thorough review scrutinizes and contrasts the attributes of 5-axis end milling and flank milling methods, covering processing principles, unique characteristics, and the implications of tool geometry. Regarding these two milling methods, the paper summarizes the current research findings on milling strategies for free-form surface blade fabrication and the evaluation and management of errors and deformations in the machining of thin-walled blades. Moreover, it delves into the challenges and innovative technological solutions in tool-path planning and deformation control within 5-axis milling. This paper aims to furnish technical guidance for the manufacture of CIs, thereby charting a path towards the realization of high-performance and cost-efficient CIs.