Spline-constrained tool-path planning in five-axis flank machining of ruled surfaces

Previous optimization-driven tool-path planning methods provide an effective approach to machining error control in five-axis flank milling of ruled surfaces. However, the finished part typically exhibits poor surface roughness. This paper proposes a new planning method for overcoming this problem. The proposed method generates a spline-curve-constrained tool path that produces minimized geometrical deviations on the machined surface, maintains satisfactory surface quality, and reduces the dimensionality in the solution space. A particle swarm optimization scheme was developed to determine the coefficients of the curve equations defining the constrained tool motion. A machining experiment was conducted and the measurement results validated the proposed method.