Five-axis tool orientation smoothing using quaternion interpolation algorithm

In five-axis machining, abrupt changes of tool axes may deteriorate the part surface, hence smoothing of tool orientations becomes an important issue. In the present tool path generation procedure, the tool orientation smoothing method (TOS method) is coupled with the cutting error improvement method (CEI method). TOS method is used to smooth tool orientations in order to reduce cutting errors and increase the machining efficiency. CEI method modifies existing cutter location data (CL data) so that final cutting errors are kept within the required tolerance. Experimental results show that the tool paths generated by the present procedure have better machining efficiency, better surface quality, and no interferences between the tool and part surfaces. (C) 2003 Elsevier Ltd. All rights reserved.