Optimized continuous small line interpolation algorithm for high end CNC machine tools using a cross segment approach

High-end CNC machine tools play a crucial role in modern manufacturing, requiring high precision and efficiency to meet complex machining demands. However, these systems face significant challenges, including the need to monitor multiple performance measures such as feed stability, interpolation precision, and processing speed, along with managing intricate curved data and meeting stringent cutting standards. These performance measures, collectively referred to as numerical control indicators in this work, provide an objective basis for evaluating machining quality and algorithm efficiency. To address these challenges, optimizing interpolation strategies has become a key research focus in high-end CNC machining. Enhancing interpolation accuracy and efficiency is essential for improving machining quality while reducing computational complexity and processing time. The main aim of this paper is to propose a continuous small-line interpolation algorithm based on cross-segment optimization. This algorithm interpolates machining trajectories and spline curves while minimizing numerical control complexity and shortening processing time. By employing a 1/2 search method and leveraging front and rear segment data, the algorithm improves interpolation accuracy to over 95%, meets bow height error requirements, and reduces computation time by 10-15%. Simulation results confirm that the proposed method significantly enhances numerical control performance. Under complex workpiece constraints, the interpolation strategy of constant speed within a segment and cross-section transfer effectively determines the shortest milling cutter path, reducing workpiece wear and optimizing machining efficiency. The findings demonstrate that the proposed algorithm not only improves CNC precision and processing speed but also offers broad applicability to similar CNC machine tools.