A control algorithm for rapid movements near the radius compensation singularity in five-axis end milling

When the five-axis CNC system executes the 3D cutter radius compensation function, the angle between two adjacent radius compensation vectors might become very large and the linear axes would move too fast if the tool orientation vector is close to the surface normal. The reason that results in this phenomenon is analyzed based on building the transmission relationship between the cutter contact point and the cutter location point. By taking the square-end tool as an example, an optimization algorithm to control the undesired movements is advanced. For the singular area where sudden change exists, the number of interpolation cycles is determined by the cutter feedrate, the limit speeds of machine axes and the maximum allowable angle between radius compensation vectors of adjacent NC blocks. The radius compensation vector of each interpolation cycle is obtained by a kind of vector rotation method. By maintaining the perpendicularity between the radius compensation vector and the tool orientation vector, the rapid movements of the linear axes are eliminated. A trial-cut experiment is performed to verify the correctness and the effectiveness of the proposed algorithm.