Contour Deviation Consistency Controlling Method for Turning Toolpaths of Complex Surfaces

doi:10.3901/JME.260390

Abstract

Abstract: High-precision physics experiments, aerospace engineering and other high-tech and industrial fields have a significant demand for complex surface parts. A particular type of them is commonly designed with unrotational-symmetric features such as sudden changes in local curvature, non-uniform low-frequency undulations, and sharp contour variations. Slow tool servo turning is an effective method for creating these surfaces. However, due to the high sensitivity of unrotational-symmetric complex surfaces to factors within the tolerance limits of conventional accuracy, even minor process differences can have a significant impact on machining accuracy, making it challenging to maintain consistent accuracy for the whole region. To address the challenges of quality control in the slow tool servo turning of unrotational-symmetric complex surfaces, a contour deviation consistency controlling method for turning toolpaths is proposed. This approach constructs a normal equidistant offset surface of the unrotational-symmetric complex surface as the target for toolpath planning, and generates discretized toolpaths for PVT interpolation based on this surface. A local sparsification and densification strategy is developed for cutter location points constrained by PVT interpolation deviations, and an iterative optimization method is proposed to adjust cutter location points while maintaining consistency of contour deviations between adjacent points. A machining verification experiment is conducted using a rotating wave surface abstracted from the sealing ring of a nuclear main pump as a typical sample. The results show that the produced sample using the proposed method can reduce profile error by 32.61%, root mean square profile error by 36.36% and surface roughness by 28.03% compared to conventional equal parameter method, significantly improving the machining accuracy and surface quality for slow tool servo turning of complex surfaces.

Key words: slow tool servo turning, unrotational-symmetric complex surface, toolpath planning, contour deviation consistency, PVT interpolation

CLC Number:

TH161

MA Jianwei, LI Guanlin, XIE Yinghao, SHEN Yuantong, JIA Zhenyuan. Contour Deviation Consistency Controlling Method for Turning Toolpaths of Complex Surfaces[J]. Journal of Mechanical Engineering, 2026, 62(7): 452-461.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260390

http://www.cjmenet.com.cn/EN/Y2026/V62/I7/452

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