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Real-time estimate and control contour errors for five-axis local smoothed toolpaths based on airthoid splines

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Abstract

Five-axis linear commands are blended as the local smoothed toolpaths by inserting clothoid and airthoid splines at corners in five-axis CNC machining. The contour error is the bottleneck to achieve the precise dimension of the machined parts, when following the local smoothed toolpaths. This paper presents a contour error estimation and control method for the five-axis smoothed toolpaths with airthoid splines, according to the geometric characteristics of the toolpaths. The tool-tip contour error is analytically calculated based on the expression of the smoothed toolpaths. Consequently, the tool-orientation contour error is obtained by synchronizing the tool-orientation contour point with the tool-tip item based on the motion time through the designed time scale coefficient, when the toolpaths are scheduled by the time-synchronization scheme. Furthermore, a contour error compensation strategy is constructed to adaptively determine the compensator gain. It can be qualified to maximally eliminate the contour errors and steadily hold the control stability of the feed drives, in spite of the modeling error between the nominal and actual control models. The simulation and experiment results show that the estimation algorithm has higher accuracy than traditional methods, and the compensation strategy effectively eliminates the five-axis contour error.

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Funding

This work was financially supported by the National Natural Science Foundation of China under Grant nos. 52105512, 52275483, 52075142, the Major Science and Technology Projects of Anhui Province under Grant no.202003a05020033 and the Fundamental Research Funds for the Central Universities under Grant no.JZ2021HGQA0217.

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Authors and Affiliations

  1. School of Mechanical Engineering, Hefei University of Technology, 230009, Hefei, Anhui, China

    Xiaoyong Huang, Baoqing Chen, Shan Chen, Daoyang Yu & Jiang Han

  2. Anhui Engineering Laboratory of Intelligent CNC Technology and Equipment, Hefei University of Technology, 230009, Hefei, Anhui, China

    Xiaoyong Huang, Baoqing Chen, Xiaoqing Tian, Shan Chen, Daoyang Yu & Jiang Han

  3. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, 710049, Xi’an, Shaanxi, China

    Xiaoyong Huang, Xiaoqing Tian & Xuesong Mei

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  1. Xiaoyong Huang
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  4. Shan Chen
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Contributions

Xiaoyong Huang: Investigation, Methodology, Writing original draft. Baoqing Chen: Investigation, Validation, Data curation. Xiaoqing Tian: Investigation, Resources, Supervision, Funding acquisition. Shan Chen: Investigation, Validation, Data curation. Daoyang Yu: Investigation, Validation, Data curation. Jiang Han: Project administration, Investigation, Methodology. Xuesong Mei: Project administration, Investigation, Methodology.

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Correspondence to Xiaoqing Tian or Xuesong Mei.

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Huang, X., Chen, B., Tian, X. et al. Real-time estimate and control contour errors for five-axis local smoothed toolpaths based on airthoid splines. Int J Adv Manuf Technol 127, 1483–1504 (2023). https://doi.org/10.1007/s00170-023-11363-8

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