Real-time measurement-based optimization of tool position and tool axis vector for five-axis machining using interpolated cutter contact point

Abstract In five-axis machining, nonlinear errors arise due to deviations between the interpolated cutter contact point (CCP) and the tool cutting edge profile, which negatively impacts machining accuracy and surface quality. To address this challenge, a real-time optimization method for both tool position and tool axis vector is proposed, based on the interpolated CCP. First, a cutting profile surface calculation is introduced, enabling the determination of the shortest distance between the interpolated CCP and the cutting profile. This allows precise compensation of CCP errors caused by overcutting or undercutting, improving machining accuracy. Additionally, a hybrid interpolation method combining linear interpolation and quaternion spherical linear interpolation (SLERP) is employed to ensure smooth transitions in tool axis orientation. This approach maintains computational efficiency while providing stability in regions with large angular variations. Experimental results show that the proposed method significantly reduces CCP errors and surface roughness, enhancing machining precision and surface quality. The approach demonstrates high efficiency and reliability in machining complex surfaces, offering a robust solution for high-precision applications in five-axis machining.