Research on generation of toolpaths with smooth tool orientation changes for five-axis machining of blisk based on the rotary axes kinematic features of machine tool

Path planning in five-axis machining is a critical step in transitioning a blisk from design to its final form. However, for a typical five-axis machine tool, since the rotary axes have a larger moment of inertia than the three linear axes, the significant moment of inertia makes the rotary axes less responsive to rapid trajectory changes, especially under high-speed interpolation or frequent reorientation, which can potentially lead to tracking delays and position deviations. It is desirable to minimize the use of two rotary axes (especially the axis with a larger moment of inertia) when planning tool paths, in order to fully utilize the kinematic capabilities and dynamic performance of the machine tool, reduce energy consumption (for driving the machine tool), improve machining efficiency, and achieve green manufacturing. In this study, a new method for smoothing the tool orientation changes of blisk machining based on the interference-free geometry feasible region (GFR) and the kinematic characteristics of machine tool is proposed, which attempts to minimize the use of the rotary axes (especially the rotary axis with the maximum moment of inertia), considering the kinematic characteristics of five axis machine tools while tending towards all given constraints. The computer simulation and physical cutting experiments of the proposed method were preliminarily confirmed, and the feasibility and advantages of the proposed method were compared with UG-NX. The simulation and experimental results demonstrate that the application of this method, with a surface roughness of 1.5 μm and a geometric accuracy of within 0.07 mm. It is worth mentioning that the proposed method has a smaller amplitude of change in the rotation axis compared to UG, due to consideration of the machine tool's kinematic performance.