Optimized dual NURBS curve interpolation for high-accuracy five-axis CNC path planning

Area of Science:

• Manufacturing Engineering
• Computer-Aided Manufacturing
• Geometric Modeling

Background:

• Modern manufacturing demands high-precision and efficiency, making five-axis CNC systems essential for complex surfaces.
• Traditional interpolation methods struggle with synchronous control of tool position and orientation in five-axis machining.

Purpose of the Study:

• To develop and validate a novel dual NURBS curve interpolation algorithm for five-axis synchronized motion.
• To improve machining accuracy, efficiency, and surface quality for complex geometries.

Main Methods:

• A master-slave curve strategy was employed for dual NURBS interpolation, controlling tool path and orientation synchronously.
• Simulation experiments were conducted on Spiral, Blade, and Freeform surfaces.

Main Results:

• The dual NURBS method achieved a maximum chord error of 0.0006 mm and average error of 0.0004 mm, significantly outperforming traditional methods.
• Reduced chord error by over 68.6% and improved processing efficiency by more than 16% compared to conventional techniques.
• Demonstrated smooth velocity planning with speed fluctuations within 10 mm/s, minimizing tool vibration and surface defects.

Conclusions:

• The dual NURBS interpolation algorithm effectively enhances machining accuracy and efficiency for complex five-axis CNC operations.
• This method offers a robust solution for high-precision surface processing in industrial manufacturing.
• The findings confirm significant improvements in path smoothness, reduced errors, and better efficiency.