A tool path generation method based on smooth machine rotary angle and tilt angle in five-axis surface machining with torus cutters

To solve the problem of the poor machining quality of the leading and trailing edge surface of the aircraft engine blade, a tool path generation method based on smooth machine rotary angle and tilt angle in five-axis surface machining with torus cutters was proposed. In terms of a specified type of five-axis machine tool, a relationship equation between design variables of tool position and machine rotary angles was firstly derived. A new tool orientation smoothing approach was then put forward. On this foundation, a tool path generation method based on a smooth machine rotary angle and tilt angle was presented. Finally, an aircraft engine blade was used as an example. The angular variation, angular velocity, and acceleration of the machine rotary axes produced by the Sturz method and the proposed method were compared and analyzed. Also, cutting trials were performed on the specified 5-axis machine tool. Experimental and comparison results proved that the proposed method can shorten the actual machining time, avoid the abrupt change of machine rotary axes, make the movement of machine axes more stable and smoother, and obtain better machining quality.