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<p>In five-axis machining of sculptured surfaces, achieving tight geometric accuracy at high productivity is often limited by servo-induced tracking deviations that increase rapidly with feedrate. This paper presents FSTEP, a real-time feedrate scheduling scheme that predicts trajectory deviations ahead of execution and adjusts the commanded feedrate accordingly. The method continuously updates feed-axis dynamic parameters online and propagates the predicted axis responses through five-axis kinematics to estimate the upcoming tool-tip deviation in the workpiece frame. A feed bound is then computed from a deviation-to-feed mapping with a safety margin, enabling accuracy-constrained feed override without requiring a particular path parameterisation. The approach is directly applicable to both linear segments and general curved trajectories. Simulations and cutting tests on free-form parts demonstrate that FSTEP maintains a machining time comparable to existing methods while keeping the predicted deviation within the prescribed tolerance.</p>

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Real-time trajectory error prediction-based feedrate scheduling for five-axis machining

  • 期刊论文

  • 发表日期：

    2026年3月15日

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  • Hengbo Li,
  • Haorong Zhang,
  • Fei Lou,
  • Zhebin Shen,
  • Yijie Wu

摘要

In five-axis machining of sculptured surfaces, achieving tight geometric accuracy at high productivity is often limited by servo-induced tracking deviations that increase rapidly with feedrate. This paper presents FSTEP, a real-time feedrate scheduling scheme that predicts trajectory deviations ahead of execution and adjusts the commanded feedrate accordingly. The method continuously updates feed-axis dynamic parameters online and propagates the predicted axis responses through five-axis kinematics to estimate the upcoming tool-tip deviation in the workpiece frame. A feed bound is then computed from a deviation-to-feed mapping with a safety margin, enabling accuracy-constrained feed override without requiring a particular path parameterisation. The approach is directly applicable to both linear segments and general curved trajectories. Simulations and cutting tests on free-form parts demonstrate that FSTEP maintains a machining time comparable to existing methods while keeping the predicted deviation within the prescribed tolerance.