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<p>In five-axis CNC machining, dynamic control errors caused by servo system deficiencies are the primary source of inaccuracies during high-speed precision operations. The S-shaped test piece has been validated as an effective method for dynamic control accuracy evaluation; thus, its integration into nonmachining rotation tool centre point (RTCP) testing offers material and time cost advantages. In this study, a standardized miniaturized S-shaped RTCP test is proposed as a pretest or partial substitute for conventional S-shaped workpiece evaluations. The method involves generating an S-shaped trajectory using two fourth-order quasi-uniform rational B-splines, which are reduced to 1/100 of the original size to match the RTCP device constraints. The mechanism and characteristics of dynamic control errors are analysed, with standardized trajectory generation and test settings introduced to eliminate planning uncertainties. A comparative analysis of the axis motions between the mini S-shaped test and the S-shaped test piece demonstrates their similarity during the test process. Both the simulation and experimental results confirm that the mini S-shaped RTCP test captures analogous error patterns and sensitivity to dynamic control errors, validating its suitability as a pretest or partial substitute for assessing dynamic control accuracy under complex five-axis trajectories.</p>

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Scale-down S-shaped RTCP test as a pretest and partial substitute for the S-shaped test piece in the dynamic control accuracy evaluation of five-axis machine tools

  • 期刊论文

  • 发表日期：

    2026年7月3日

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  • Qicheng Ding,
  • Chenhui Hua,
  • Wei Wang

摘要

In five-axis CNC machining, dynamic control errors caused by servo system deficiencies are the primary source of inaccuracies during high-speed precision operations. The S-shaped test piece has been validated as an effective method for dynamic control accuracy evaluation; thus, its integration into nonmachining rotation tool centre point (RTCP) testing offers material and time cost advantages. In this study, a standardized miniaturized S-shaped RTCP test is proposed as a pretest or partial substitute for conventional S-shaped workpiece evaluations. The method involves generating an S-shaped trajectory using two fourth-order quasi-uniform rational B-splines, which are reduced to 1/100 of the original size to match the RTCP device constraints. The mechanism and characteristics of dynamic control errors are analysed, with standardized trajectory generation and test settings introduced to eliminate planning uncertainties. A comparative analysis of the axis motions between the mini S-shaped test and the S-shaped test piece demonstrates their similarity during the test process. Both the simulation and experimental results confirm that the mini S-shaped RTCP test captures analogous error patterns and sensitivity to dynamic control errors, validating its suitability as a pretest or partial substitute for assessing dynamic control accuracy under complex five-axis trajectories.