Abrasive waterjet (AWJ) is widely applied in 2D machining as it offers high machining efficiency and low machining cost. However, machining a 3D surface, especially for a small curvature radius freeform surface (SCRFS), results in over-erosion of the corner, and has been one of the greatest issues of AWJ. To solve this problem, a local smoothing algorithm for SCRFS is developed by the junction of two linear segments at the corner by inserting cubic second-order B-spline to smooth the nozzle path and posture under the setting tolerance error, which is aimed to avoid over-erosion due to the change in dwell time. Analytical solutions of the smooth corner position and orientation of the nozzle path are obtained by evaluating a synchronization algorithm. According to the set tolerance error of the nozzle position and orientation, the interpolation of the smooth path of the corner meets the constraint conditions of the linear feed drive. Path simulation and experimental results show that the proposed method is validated by the experimental results and has been applied to the integral blisk machining of an aero-engine.

加砂水刀 (AWJ) 具有加工效率高、加工成本低等优点，广泛应用于二维加工。然而，加工 3D 表面，特别是对于小曲率半径自由曲面 (SCRFS)，会导致转角过度腐蚀，这一直是 AWJ 的最大问题之一。为了解决这个问题，通过插入三次二阶 B 样条在拐角处的两条直线段的交界处开发了一种 SCRFS 的局部平滑算法，以在设置的公差误差下平滑喷嘴路径和姿态，旨在避免由于停留时间的变化而引起的过度腐蚀。通过评估同步算法获得了喷嘴路径的平滑拐角位置和方向的解析解。根据喷嘴位置和方向的设定公差误差，转角平滑路径的插补满足直线进给驱动的约束条件。路径仿真和实验结果表明，该方法得到实验结果的验证，并已应用于航空发动机整体叶盘加工。