Toolpath interpolation with novel corner smoothing technique

Abstract

• Propose a novel filter-based corner smoothing with double filter technique for CNC machining. • Derive analytical formulations for contour errors with satisfying kinematic constraints. • Design filter order and corner speed to ensure that acceleration, jerk and contour error. • Achieve higher machining efficiency and contour accuracy as compared to the state-of-art technique. In this study, a novel filter-based corner smoothing with double filter (FCSDF) technique is proposed to generate interpolated trajectories for high-speed machine tools. The technique uses a double filter to smooth segment junctions and limit axial jerk. The novelty of this study is to derive an analytical formulation for corner contour error and to find the relationship between corner speed and contour error. The FCSDF algorithm provides a systematic way to design filter order and to determine the corner speed to ensure that acceleration, jerk and contour error are confined. As a result, the technology can achieve both high machining accuracy and efficiency and is easy to implement in real time. Finally, the FCSDF is validated using a multisegment trajectory, and the experimental results verify the effectiveness in improving the contouring performance and cycle time.