Global tool axis vector optimization based on the minimum angular acceleration of rotary axes

The parts with complex surface are widespread application for industrial manufacturing field, and 5-axis machining with ball-end cutter is a common measure for surface machining. In order to achieve high-quality surface machining, it is especially important to optimize the pose of the tool and the workpiece. The local tool axis vector optimization can effectively reduce the machining error of the complex surface parts with abrupt curvature. However, when tool axis vectors optimizing interval is overmuch, the local tool axis vector optimization is time-consuming and ineffective. To solve this defect, aiming at the minimum angular acceleration, a global tool axis vector control method is proposed in this research. Firstly, the feasible spaces of the tool axis vectors at the CC (cutter contact) points are obtained. Then, the toolpath is divided by the property of concavity or convexity for the toolpath curve, and the key tool axis vectors on the toolpath curve are determined. Finally, tool axis vectors are adjusted based on the minimum rotary axes’ angular acceleration in each interval, and the tool axis vectors at the joint position of the adjacent segments are adjusted to smooth tool axis vectors for the entire toolpath. Through the simulation and experiment on the test part, the validity of the method is proved, and the global optimization method can effectively decrease the machining errors and promote the machining quality of the complex surface.