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<p>Five-axis machining technology is widely used to manufacture complex surface parts. However, during the machining process, the swing of the rotary axes and the nonlinear mapping of numerous minor linear segment interpolations cause the actual tool trajectory to deviate from the predefined theoretical trajectory, resulting in nonlinear errors. A cutter contacting (CC) point trajectory optimization method is proposed to effectively control the magnitude of nonlinear errors. This study focuses on an A-C TT type five-axis CNC machine tool, establishing the forward and inverse kinematics models, along with the linear interpolation trajectory equations, to compute the interpolated tool center (TC) point coordinates and the interpolated cutter axis vector. Then, based on envelope theory, a geometric model of the toroidal cutter is constructed. The cutting contour surface equation of the tool is derived, and the interpolated CC point coordinates are calculated using the cutting contour surface equation. Based on the CC point data, a nonlinear error calculation and compensation model is established, optimizing the CC point trajectory and effectively controlling the Magnitude of the nonlinear error. Simulation using MATLAB and UG software, along with practical machining validation, demonstrates that the proposed method achieves synchronous correction of both the TC point and CC point trajectories, reducing the nonlinear error from 38.6 μm before compensation to 3.71 μm, a reduction of 90.3%. This technology efficiently reduces nonlinear errors and alleviates overcutting and undercutting issues, offering substantial practical benefits for enhancing the machining precision of intricate surfaces.</p>

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Optimization of cutter contact point trajectory and nonlinear error control method for five-axis machining based on cutting contour surface

  • 期刊论文

  • 发表日期：

    2025年9月15日

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  • Liangji Chen,
  • Haocheng Lian,
  • Zhijin Huang,
  • Guihai Wang,
  • Huiying Li,
  • Haohao Xu

摘要

Five-axis machining technology is widely used to manufacture complex surface parts. However, during the machining process, the swing of the rotary axes and the nonlinear mapping of numerous minor linear segment interpolations cause the actual tool trajectory to deviate from the predefined theoretical trajectory, resulting in nonlinear errors. A cutter contacting (CC) point trajectory optimization method is proposed to effectively control the magnitude of nonlinear errors. This study focuses on an A-C TT type five-axis CNC machine tool, establishing the forward and inverse kinematics models, along with the linear interpolation trajectory equations, to compute the interpolated tool center (TC) point coordinates and the interpolated cutter axis vector. Then, based on envelope theory, a geometric model of the toroidal cutter is constructed. The cutting contour surface equation of the tool is derived, and the interpolated CC point coordinates are calculated using the cutting contour surface equation. Based on the CC point data, a nonlinear error calculation and compensation model is established, optimizing the CC point trajectory and effectively controlling the Magnitude of the nonlinear error. Simulation using MATLAB and UG software, along with practical machining validation, demonstrates that the proposed method achieves synchronous correction of both the TC point and CC point trajectories, reducing the nonlinear error from 38.6 μm before compensation to 3.71 μm, a reduction of 90.3%. This technology efficiently reduces nonlinear errors and alleviates overcutting and undercutting issues, offering substantial practical benefits for enhancing the machining precision of intricate surfaces.