ABSTRACT This paper investigates the five-axis continuous machining strategy on cost-effective five-axis CNC milling systems, which is limited by simultaneous control of any four axes at a given time. The proposed strategy consists of (1) generation of five-axis continuous milling tool path for conventional five-axis machines using a CAD/CAM software, and (2) conversion of the generated tool path to four-axis tool trajectory based on a novel interpolation algorithm. The interpolation algorithm is built on the relationship between the position data of the tool and the displacement of the machine tool axis. The position of the interpolation point is determined by the offset distance of the interpolation point, and the error of the interpolation is controlled by the dichotomy method. Furthermore, two simulation case studies are conducted to verify the effectiveness of the proposed algorithm. One case study is on a standard ‘S’ test piece, and the other study is on a more complicated geometry – an impeller part. The generated five-axis continuous paths are converted to the four-axis trajectory by the proposed algorithm. Machining simulations are performed using both the five-axis continuous path and the converted four-axis continuous path. The conversion quality is found to be satisfactory for both cases.

中文翻译：

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为具有四轴控制器的经济高效的五轴 CNC 铣削系统开发连续加工策略

摘要本文研究了具有成本效益的五轴数控铣削系统的五轴连续加工策略，该系统受到在给定时间同时控制任何四个轴的限制。所提出的策略包括（1）使用 CAD/CAM 软件为传统五轴机床生成五轴连续铣削刀具路径，以及（2）基于一种新颖的方法将生成的刀具路径转换为四轴刀具轨迹。插值算法。插补算法建立在刀具位置数据与机床轴位移之间的关系上。插值点的位置由插值点的偏移距离确定，插值误差通过二分法控制。此外，进行了两个仿真案例研究来验证所提出算法的有效性。一个案例研究是关于标准的“S”试件，另一个研究是关于更复杂的几何形状——叶轮零件。通过所提出的算法将生成的五轴连续路径转换为四轴轨迹。使用五轴连续路径和转换后的四轴连续路径进行加工模拟。发现两种情况的转换质量都令人满意。使用五轴连续路径和转换后的四轴连续路径进行加工模拟。发现两种情况的转换质量都令人满意。使用五轴连续路径和转换后的四轴连续路径进行加工模拟。发现两种情况的转换质量都令人满意。