Enhancing five-axis CNC toolpath smoothing: Overlap elimination with asymmetrical B-splines

In the realm of five-axis Computer Numerical Control (CNC) machining, the challenge of minimizing velocity, acceleration, and jerk fluctuations has prompted the development of various local corner smoothing methods. However, existing techniques often rely on symmetrical spline curves or impose pre-set transition length constraints, limiting their effectiveness in reducing curvature and maintaining velocity at critical corners. To comprehensively address these limitations comprehensively, a novel approach for local smoothing of five-axis linear toolpaths is presented in this paper. The proposed method introduces two asymmetrical B-splines at corners, effectively smoothing both the tool-tip position in the workpiece coordinate system and the tool orientation in the machine coordinate system. To fine-tune transition curve scales and minimize velocity disparities between adjacent corners, an overlap elimination scheme is employed. Furthermore, the two-step strategy emphasizes the synchronization of tool-tip position and tool orientation while considering maximal approximation error. The outcome is a blended five-axis toolpath that significantly reduces curvature extremes in the smoothed path, achieving reductions ranging from 36.28 % to 45.51 %. Additionally, the proposed method streamlines the interpolation process, resulting in time savings ranging from 5.68 % to 8.78 %, all the while adhering to the same geometric and kinematic constraints.