Abstract Five-axis CNC flank machining has been commonly used in the industry for shaping complex geometries. Geometrical errors typically occur in five-axis flank finishing of non-developable surfaces using a cylindrical cutter. Most existing tool path planning methods adjust discrete cutter locations to reduce these errors. An excessive change in the cutter center or axis between consecutive cutter locations may deteriorate the machined surface quality. This study developed a tool path generation method for minimizing geometrical errors on finished surfaces while preserving high-order continuity in the cutter motion. A tool path is described using the moving trajectory of the cutter center and changes in two rotational angles in compact curve representations. An optimization scheme is proposed to search for optimal curve control points and the resulting tool path. A curve subdivision mechanism progressively increases the control points during the search process. Simulation results confirm that the proposed method not only enhances the computational efficiency of tool path generation but also improves the machined surface finish. This study provides a computational approach for precision tool path planning in five-axis CNC flank finishing of ruled surfaces.

中文翻译：

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连续保持刀具路径生成，以最大限度地减少直纹曲面五轴 CNC 侧面铣削中的加工误差

摘要 五轴数控后刀面加工已在工业中广泛用于塑造复杂的几何形状。几何误差通常发生在使用圆柱刀具对不可展开表面进行五轴后刀面精加工时。大多数现有刀具路径规划方法调整离散刀具位置以减少这些错误。连续刀具位置之间刀具中心或轴的过度变化可能会降低加工表面质量。本研究开发了一种刀具路径生成方法，可最大限度地减少成品表面的几何误差，同时保持刀具运动的高阶连续性。使用刀具中心的移动轨迹和紧凑曲线表示中两个旋转角度的变化来描述刀具路径。提出了一种优化方案来搜索最佳曲线控制点和由此产生的刀具路径。曲线细分机制在搜索过程中逐步增加控制点。仿真结果证实，所提出的方法不仅提高了刀具路径生成的计算效率，而且提高了加工表面光洁度。本研究为直纹曲面五轴 CNC 侧面精加工中的精密刀具路径规划提供了一种计算方法。