Hierarchical design, dimensional synthesis, and prototype validation of a novel multi-spindle 5-axis machine tool for blisk machining

In order to improve machining efficiency and quality of aero-engine blisks, a novel multi-spindle 5-axis machine tool is developed under the inspiration of the blisk structure. The proposed machine contains 8 spindles, which are arranged radially along the blisk and simultaneously participate in machining. The actuator of the machine contains three rotation axes and two translation axes, which can realize 5-axis CNC machining. Based on the unified kinematics model, the mechanism is analyzed in terms of forward and inverse kinematics, singularity, and flexible workspace. Meanwhile, the structural parameters of the machine are optimized according to the flexibility index to improve the kinematic performance of the mechanism. Theoretical and experimental results show that the machine tool has a more compact structure, fewer moving axes, and better kinematics performance, compared with the traditional multi-spindle modular machine tool. Therefore, the machine has significant advantages in processing efficiency and has great application potential in large batch machining of the blisk.