Abstract: A springback along the chord-wise direction is occurred in the rolling process of the high pressure compressor blade in aero-engine, which affects the accuracy of the blade profile directly and then affects the service performance of the engine. In order to achieve the net-shape of the compressor blade for the aero-engine by rolling, an optimized designing method is presented to improve the accuracy of rolling cavity surface by mapping transformation of the section curves, which compensated the springback on the original section contours. The deformation of the sheet metal in bending process is analyzed, and a model which described the variation of central angle before and after springback is studied. After that, a springback compensation method for blade section is proposed and the springback deviation of every process model's section curve is compensated. The springback compensated section curves are mapped to a sector in three dimension around the rollers' axes, and the rolling cavity surfaces are reconstituted through the mapped section curves. An effective numerical calculation method is used to simulate the blade rolling process by both the original cavity surfaces and the springback compensated cavity surfaces in order to obtain the shapes of corresponding deformed blades. The results show that the optimal designing of mold cavity can improve the precision of compressor blade profile effectively, and that the deviation of the deformed blade is decreased to 16.7% comparing with the original results. The springback compensating method, which provides a theoretical foundation for designing roller cavity surfaces, would contribute to achieving the net shape profile of the rolling compressor blade. Meanwhile, the method offers a foundation for improving the precision of the irregular sheet metal in plastic deformation.

Key words: compressor blade, optimization design, roller cavity, section curves, shaping accuracy, springback compensation