Tiny linear toolpaths widely used in five-axis CNC machine tools only meet G0 continuity at the junctions of adjacent paths, the tangential and curvature discontinuities at the corners result in decelerations and fluctuations of machine tools. Although the corner smoothing for the three-axis tool path is relatively mature, the five-axis tool pose path smoothing is still difficult to plan due to the nonlinear motions of the rotational axes and the parameter synchronization between the tool center point (TCP) path and the tool orientation vector (TOV) path. Therefore, this paper aims to extend the smoothing scopes of previously presented mixed tiny path smoothing method based on sliding convolution windows for three-axis CNC machining (Zhang et al. in Journal of Manufacturing Process 102:685–699, [19]). Compared with the previous work, this paper converts the five-axis tool pose path into the tool position signal and tool orientation signal, and the interpolation points of the two path signals in the convolution window are directly processed on the basis of the synchronous motions of all axes. The original parameter synchronization relationship between the TCP path and the TOV path is still maintained. Besides, the smoothing error prediction model is constructed. The proposed five-axis path smoothing method has been integrated into a self-developed open-architecture CNC system and its effectiveness for the five-axis path optimization is validated via the simulation and experiment.

五轴数控机床广泛采用的微小直线刀具路径仅在相邻路径的交汇处满足G0连续性，拐角处的切向和曲率不连续导致机床减速和波动。尽管三轴刀具路径的拐角平滑已经相对成熟，但由于旋转轴的非线性运动以及刀具中心点（TCP）路径之间的参数同步，五轴刀具位姿路径平滑仍然难以规划以及工具方向矢量 (TOV) 路径。因此，本文旨在扩展先前提出的基于滑动卷积窗口的三轴数控加工混合微路径平滑方法的平滑范围（Zhang et al. in Journal of Manufacturing Process 102:685–699, [19]）。与前人的工作相比，本文将五轴刀具位姿路径转换为刀具位置信号和刀具方位信号，并根据五轴刀具的同步运动直接对两个路径信号在卷积窗口中的插补点进行处理。所有轴。TCP路径和TOV路径之间仍保持原有的参数同步关系。此外，还构建了平滑误差预测模型。所提出的五轴路径平滑方法已集成到自主开发的开放式数控系统中，并通过仿真和实验验证了其五轴路径优化的有效性。