Smoothing and compressing algorithm of toolpath with complex contour in NC machining

The continuous short line segment processing method in CNC machining has the defect of frequent fluctuation of feedrate, which affects the quality and efficiency. For this problem, the local and global methods are common solutions. The local method is to insert transition curves at the corners to ob...

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Published in:	International journal of advanced manufacturing technology Vol. 125; no. 9-10; pp. 4841 - 4854
Main Authors:	Zhang, Liang, Lu, Juan, Ou, Chengyi, Ma, Junyan, Liao, Xiaoping
Format:	Journal Article
Language:	English
Published:	London Springer London 01.04.2023 Springer Nature B.V
Subjects:	Advanced manufacturing technologies Algorithms Application CAE) and Design Computer-Aided Engineering (CAD Contours Cutting force Data compression Deceleration Design Efficiency Engineering Error reduction Industrial and Production Engineering Interpolation Least squares method Machine tools Machining Manufacturing Mechanical Engineering Media Management Methods Numerical controls Search engines Segments Software Straight lines Trajectories NURBS curves Least squares method Toolpath smoothing Generation of toolpaths
ISSN:	0268-3768, 1433-3015
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Abstract	The continuous short line segment processing method in CNC machining has the defect of frequent fluctuation of feedrate, which affects the quality and efficiency. For this problem, the local and global methods are common solutions. The local method is to insert transition curves at the corners to obtain a smooth toolpath, but this method does not essentially reduce the number of accelerations and decelerations, and it is difficult to insert transition curves between tiny straight sections. Although the global method can obtain smooth tool trajectories, the parametric interpolation method is not suitable for middle- and low-end CNC machine tools. The article proposes an adaptive tool path generation method with the original part contour as the research object and discretizes the NURBS curves into smooth trajectories consisting of large segments of straight lines and circular arcs. The article mimics the crawling characteristics of snakes and designs a double-headed snake algorithm based on the least squares method to implement this process. First, given the start and end points of the curve, two snakeheads search for the maximum linear and circular segments that satisfy the error constraint in the curve direction. The winner will then be selected as the candidate track segment through a competition mechanism. Finally, all trajectory segments are connected to obtain a smooth tool path. Experiments show that the toolpath data of the method in this paper are reduced by 75.56% compared with commercial CAM software when the contour error threshold is the same, and the contour error is reduced by more than one order of magnitude when the number of toolpath segments is equal. In addition, the method in this paper can obtain a smoother machining surface and more stable cutting force, thus achieving a win‒win situation of quality and efficiency.
AbstractList	The continuous short line segment processing method in CNC machining has the defect of frequent fluctuation of feedrate, which affects the quality and efficiency. For this problem, the local and global methods are common solutions. The local method is to insert transition curves at the corners to obtain a smooth toolpath, but this method does not essentially reduce the number of accelerations and decelerations, and it is difficult to insert transition curves between tiny straight sections. Although the global method can obtain smooth tool trajectories, the parametric interpolation method is not suitable for middle- and low-end CNC machine tools. The article proposes an adaptive tool path generation method with the original part contour as the research object and discretizes the NURBS curves into smooth trajectories consisting of large segments of straight lines and circular arcs. The article mimics the crawling characteristics of snakes and designs a double-headed snake algorithm based on the least squares method to implement this process. First, given the start and end points of the curve, two snakeheads search for the maximum linear and circular segments that satisfy the error constraint in the curve direction. The winner will then be selected as the candidate track segment through a competition mechanism. Finally, all trajectory segments are connected to obtain a smooth tool path. Experiments show that the toolpath data of the method in this paper are reduced by 75.56% compared with commercial CAM software when the contour error threshold is the same, and the contour error is reduced by more than one order of magnitude when the number of toolpath segments is equal. In addition, the method in this paper can obtain a smoother machining surface and more stable cutting force, thus achieving a win‒win situation of quality and efficiency.
Author	Ma, Junyan Lu, Juan Liao, Xiaoping Zhang, Liang Ou, Chengyi
Author_xml	– sequence: 1 givenname: Liang surname: Zhang fullname: Zhang, Liang organization: School of Mechanical Engineering, Guangxi University – sequence: 2 givenname: Juan surname: Lu fullname: Lu, Juan organization: Department of Mechanical and Marine Engineering, Beibu Gulf University – sequence: 3 givenname: Chengyi surname: Ou fullname: Ou, Chengyi organization: School of Mechanical Engineering, Guangxi University – sequence: 4 givenname: Junyan surname: Ma fullname: Ma, Junyan organization: School of Mechanical Engineering, Guangxi University, Guangxi Key Laboratory of Manufacturing Systems and Advanced Manufacturing Technology, Guangxi University – sequence: 5 givenname: Xiaoping surname: Liao fullname: Liao, Xiaoping email: xpfeng@gxu.edu.cn organization: School of Mechanical Engineering, Guangxi University, Guangxi Key Laboratory of Manufacturing Systems and Advanced Manufacturing Technology, Guangxi University
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Snippet	The continuous short line segment processing method in CNC machining has the defect of frequent fluctuation of feedrate, which affects the quality and...
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SubjectTerms	Advanced manufacturing technologies Algorithms Application CAE) and Design Computer-Aided Engineering (CAD Contours Cutting force Data compression Deceleration Design Efficiency Engineering Error reduction Industrial and Production Engineering Interpolation Least squares method Machine tools Machining Manufacturing Mechanical Engineering Media Management Methods Numerical controls Search engines Segments Software Straight lines Trajectories
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Title	Smoothing and compressing algorithm of toolpath with complex contour in NC machining
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