Prediction and analysis of blade deformation induced by residual stress in precision milling

Residual stress-induced deformation is a critical challenge in blade precision manufacturing, yet its underlying mechanism remains unclear, and efficient calculation methods are lacking. This study addresses these gaps by focusing on the GH4169D compressor blades, conducting experimental measurements of residual stress and deformation in precision-milled blades. Based on the inherent strain theory, the principle of equal torque, and the finite element method, a novel calculation method (MSDS-DP) was developed to predict residual stress-induced deformation. Based on MADS-DP, the mechanism by which residual stress affects position and contour deformation is revealed. Specifically, position deformation is primarily influenced by residual stress in the milling direction, while contour deformation is mainly governed by residual stress in the cutting width direction. Experimental results not only demonstrated that the prediction accuracy exceeded 80%, but also revealed significant variability of the surface residual stress and differences of the in-depth residual stress field between the milling and cutting width direction. These findings provide valuable insights into the deformation mechanism and establish a robust framework for optimizing precision manufacturing processes in aeroengine components.