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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

A Five-Axis Toolpath Corner-Smoothing Method Based on the Space of Master–Slave Movement

by
Song Gao
1,2,
Haiming Zhang
1,
Jianzhong Yang
1,2,
Jiejun Xie
1,* and
Wanqiang Zhu
1
1
National NC System Engineering Research Center, Huazhong University of Science and Technology, Wuhan 430074, China
2
National Center of Technology Innovation for Intelligent Design and Numerical Control, Wuhan 430074, China
*
Author to whom correspondence should be addressed.
Machines 2024, 12(12), 834; https://doi.org/10.3390/machines12120834
Submission received: 15 October 2024 / Revised: 19 November 2024 / Accepted: 20 November 2024 / Published: 21 November 2024
(This article belongs to the Section Advanced Manufacturing)

Abstract

The smoothing of linear toolpaths plays is critical in improving machining quality and efficiency in five-axis CNC machining. Existing corner-smoothing methods often overlook the impact of spline curvature fluctuations, which may lead to acceleration variations, hindering surface quality improvements. The paper presents a five-axis toolpath corner-smoothing method based on the space of master–slave movement (SMM), aiming to minimize curvature fluctuations in five-axis machining and improve surface quality. The concept of movement space in master–slave cooperative motion is introduced, where the tool tip position and tool orientation are decoupled into a main motion trajectory and two master–slave movement space trajectories. By deriving the curvature monotony conditions of a dual Bézier spline, a G2-continuous tool tip corner-smoothing curve with minimal curvature fluctuations is constructed in real-time. Subsequently, using the SMM and the asymmetric dual Bézier spline, a high-order continuous synchronization relationship between the tool tip position and tool orientation is established. Simulation tests and machining experiments show that with our smoothing algorithm, maximum acceleration values for each axis were reduced by 21.05%, while jerk was lowered by 22.31%. These results indicate that trajectory smoothing significantly reduces mechanical vibrations and improves surface quality.
Keywords: master–slave movement; five-axis machining; corner smoothing; minimal curvature fluctuation; interpolation synchronization master–slave movement; five-axis machining; corner smoothing; minimal curvature fluctuation; interpolation synchronization

Share and Cite

MDPI and ACS Style

Gao, S.; Zhang, H.; Yang, J.; Xie, J.; Zhu, W. A Five-Axis Toolpath Corner-Smoothing Method Based on the Space of Master–Slave Movement. Machines 2024, 12, 834. https://doi.org/10.3390/machines12120834

AMA Style

Gao S, Zhang H, Yang J, Xie J, Zhu W. A Five-Axis Toolpath Corner-Smoothing Method Based on the Space of Master–Slave Movement. Machines. 2024; 12(12):834. https://doi.org/10.3390/machines12120834

Chicago/Turabian Style

Gao, Song, Haiming Zhang, Jianzhong Yang, Jiejun Xie, and Wanqiang Zhu. 2024. "A Five-Axis Toolpath Corner-Smoothing Method Based on the Space of Master–Slave Movement" Machines 12, no. 12: 834. https://doi.org/10.3390/machines12120834

APA Style

Gao, S., Zhang, H., Yang, J., Xie, J., & Zhu, W. (2024). A Five-Axis Toolpath Corner-Smoothing Method Based on the Space of Master–Slave Movement. Machines, 12(12), 834. https://doi.org/10.3390/machines12120834

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