Rotation-Angle Solution and Singularity Handling of Five-Axis Machine Tools for Dual NURBS Interpolation

Abstract

Dual NURBS interpolation has been proven an essential technique for high-speed precision machining of complex surfaces. The solution of rotation angles and their derivatives is the basis of kinematic transformation and feedrate optimization in dual NURBS interpolation. The characteristics of the rotation motion of five-axis machine tools with different structures are analyzed. A generic model of dual heads of the vertical five-axis machine tool is established to unify the solution of rotation angles. Then, a generic method for solving the rotation angles and derivatives based on the vector inner product is proposed, and the solution space is analyzed. A singularity handling is given to avoid abrupt rotation angles based on the higher derivatives of the tool orientation vector. The proposed method obtained smooth rotation angles at the singularity points in the cardioid dual NURBS interpolation experiment. It reduced the machining time by 43.3% compared with the simple inverse trigonometric method based on kinematic transformation. Experiment results demonstrate that the proposed method is feasible and effective, and has significant theoretical and practical value for optimizing five-axis CNC machining.