A smooth tool path generation method for ultraprecision turning discontinuous multi-freeform-surfaces with high machining efficiency

Abstract The typical tool path of turning freeform surfaces is spiral. Usually, this kind of tool path only can deal with continuous surfaces within a circular area. If the designed surfaces are not continuous, the spiral tool path will break, which will lead to a significant increase in servo following error of ultraprecision lathe during machining. In order to reduce the servo following error, the processing speed needs to be significantly reduced, which will greatly decrease the machining efficiency. To solve this problem, a smooth tool path interpolation algorithm in the non-cutting area for ultraprecision turning discontinuous multi-freeform-surfaces is proposed. In addition, more than circular area, this method can generate smooth tool paths for discontinuous generic surfaces of quasi-revolution based on the optimized space Archimedean spiral. Finally, the effectiveness and adaptability of the method are proved through two examples.