Aero-engine fan blades often use a cavity structure to improve the thrust-to-weight ratio of the aircraft. However, the use of the cavity structure brings a series of difficulties to the manufacturing and processing of the blades. Due to the limitation of blade manufacturing technology, it is difficult for the internal cavity structure to achieve the designed contour shape, so the blade has uneven wall thickness and poor consistency, which affects the fatigue performance and airflow dynamic performance of the blade. In order to reduce the influence of uneven wall thickness, this paper proposes a grinding allowance extraction method considering the double dimension constraints (DDC) of the inner and outer contours of the hollow blade. Constrain the two dimensions of the inner and outer contours of the hollow blade. On the premise of satisfying the outer contour constraints, the machining model of the blade is modified according to the distribution of the inwall contour to obtain a more reasonable distribution of the grinding allowance. On the premise of satisfying the contour constraints, according to the distribution of the inwall contour, the machining model of the blade is modified to obtain a more reasonable distribution of the grinding allowance. Through the grinding experiment of the hollow blade, the surface roughness is below Ra0.4 μm, and the contour accuracy is between − 0.05~0.14 mm, which meets the processing requirements. Compared with the allowance extraction method that only considers the contour, the problem of poor wall thickness consistency can be effectively improved. It can be used to extract the allowance of aero-engine blades with hollow features, which lays a foundation for the study of hollow blade grinding methods with high service performance.
