The high-pressure compressor blade of aero-engine possesses compound twisted and bowed surface

small leading/trailing edge radius

difficult-to-machine material

strict design tolerance. It’s difficult to control the blade precision and surface quality with conventional forging

rolling

milling

electrochemical machining under the premise of low cost and high efficiency. Moreover

the conventional multi-axis CNC grinding suffers low efficiency and complex residual stress deformation. Therefore

this paper implements multi-spindle synchronous high-precision grinding of aero-engine blade with the reverse segmented machining method and rectangular array machine tool. By the rigidity improvement and reverse machining sequences of each segmenting part

the proposed method can ensure the datum superposition principle in the removement of flexible part local material and control the residual stress deformation perfectly. The line/surface profile error of some typical blades are fluctuant in the range of 30μm/40μm

the machining efficiency is improved by nearly 4 times. These results can not only reduce manufacturing costs of areo-engine blade greatly

but also establish the foundation for rectangular array machine tool with more spindles extension.