International Journal of Machine Tools & Manufacture最新文献

{"title":"A review of robotic machining dynamics: A new perspective based on multi-source compliance","authors":"Shihao Xin ,&nbsp;Jiawei Wu ,&nbsp;Kai Sun ,&nbsp;Ming Zhong ,&nbsp;Xiaowei Tang ,&nbsp;Fangyu Peng ,&nbsp;Rui Fu ,&nbsp;Yuhui Yu ,&nbsp;Hao Li ,&nbsp;Xiang Ni","doi":"10.1016/j.ijmachtools.2026.104397","DOIUrl":"10.1016/j.ijmachtools.2026.104397","url":null,"abstract":"<div><div>The six-degree-of-freedom series structure of robots has brought a series of advantages such as excellent processing flexibility, large working space, and in-situ processing. In recent years, it has seen significant development and is gradually being applied across multiple critical fields. However, the manufacturing demands for large components pose significant challenges to robotic machining efficiency and quality. The inherent drawbacks of the six-degree-of-freedom serial structure—insufficient dynamic rigidity, low static stiffness, and significant pose-dependent stiffness variation of the robot body—have increasingly emerged. The machining dynamics issues caused by the robot body compliance need to be given priority attention. On the other hand, as the part of the robotic milling system that directly contacts the workpiece, the tool section is also of great significance to conduct research and analysis on the machining dynamics issues caused by its compliance. Therefore, the robotic milling system is a multi-source compliant system, influenced by multiple compliant components simultaneously, and even at relatively high tooth passing frequencies, the robot body compliance is still excited. Discussing and comparing the characteristics and distinctions of research focusing on different compliant components in terms of dynamic characteristics, machining stability, and chatter suppression, for further in-depth exploration of robotic machining dynamics, forming a theoretical framework of machining dynamics with the distinctive robotic characteristics has significant guiding significance. However, there is still a lack of detailed, specific and clear reviews on robotic machining dynamics centered on the multi-source compliance characteristics of robots. Therefore, this review will comprehensively summarize and review the related research on dynamic characteristics, stability and chatter suppression in the field of robotic machining dynamics from a new perspective of multi-source compliance. Concurrently, it will summarize existing challenges in robotic machining dynamics research while outlining future development directions.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"218 ","pages":"Article 104397"},"PeriodicalIF":18.8,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147850263","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Axial hydro-extrusion: A novel stress-transformation-based method to synchronously reduce multi-dimensional deviations of profiled hollow members","authors":"Qingfeng Wang ,&nbsp;Lei Sun ,&nbsp;Wenlong Xie ,&nbsp;Deqi Hou ,&nbsp;Long Zhao ,&nbsp;Cunsheng Zhang ,&nbsp;Guannan Chu","doi":"10.1016/j.ijmachtools.2026.104399","DOIUrl":"10.1016/j.ijmachtools.2026.104399","url":null,"abstract":"<div><div>To address multi-dimensional geometric deviations in extruded profiled thin-walled hollow members, which are challenging to correct using traditional processes, this study proposes an axial hydro-extrusion method based on a novel stress-transformation mechanism for synchronous control of multi-dimensional deviations. Unlike traditional tensile-based forming, this process induces global plastic extrusion deformation through axial feeding under internal pressure, transforming non-uniform axial, circumferential, and shear stresses into a nearly uniform and predominantly compressive stress state. This shift eliminates stress gradients, thereby controlling deviations in different dimensions and enabling synchronous outer contour correction of the hollow member. First, the effect of stiffeners on wrinkling and shape accuracy of the outer contour of the hollow member in axial hydro-extrusion is analysed, establishing a critical instability internal pressure model. Next, stress states generated by different geometric deviations during fitting die deformation and their changes during axial extrusion are investigated through theoretical and simulation methods, clarifying the reasons for deviation changes in different dimensions. Additionally, a critical extrusion displacement model incorporating work hardening is developed to quantify the stress transformation process and analyse the effects of initial deviations on critical extrusion displacements. Finally, a specialised axial hydro-extrusion forming platform is designed for single-cavity and multi-cavity hollow members with various deviations, achieving over 95% reduction in dimensional deviations. This study provides a new strategy for solving the problem of multi-dimensional geometric deviation synchronisation control in complex thin-walled hollow members.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"218 ","pages":"Article 104399"},"PeriodicalIF":18.8,"publicationDate":"2026-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147850264","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanisms of reactive medium-assisted laser ablation of thermally active materials: a case study of hydrochloric film-assisted laser machining of microchannel arrays on AlN","authors":"Jiawei Liu ,&nbsp;Ni Chen ,&nbsp;Kaixuan Feng ,&nbsp;Qi Liu ,&nbsp;Yonghui Xu ,&nbsp;Xiang Li ,&nbsp;Eberhard Abele ,&nbsp;Ning He","doi":"10.1016/j.ijmachtools.2026.104388","DOIUrl":"10.1016/j.ijmachtools.2026.104388","url":null,"abstract":"<div><div>Aluminium nitride high-temperature co-fired ceramic (AlN HTCC) is a promising substrate material for electronic packaging, and the fabrication of microchannel arrays on its backside can significantly enhance its heat dissipation performance. However, the high hardness and brittleness of AlN present considerable challenges in the machining of microstructures. Therefore, this study proposes a hydrochloric film-assisted laser processing (HFALP) technique. Initially, a systematic analysis was conducted on the multi-factor energy attenuation mechanism of laser beams. Based on this, a temperature distribution model capable of accurately predicting the line-etching morphology was developed. Furthermore, through transient observations, flow field simulations, and comparative experiments under different liquid phases, this study reveals, for the first time, the intrinsic relationship between the cavitation bubble dynamic behaviour, laser, and liquid layer. This leads to the clarification of two material removal mechanisms, tunnel channel ablation and cavitation ablation, induced by multi-mechanism synergy within the ternary system of “laser-reactive medium-thermally-active material”. Finally, narrow microgrooves with an aspect ratio of 8.6:1 were successfully fabricated on AlN by coupling the two ablation mechanisms. Compared with laser chemical milling, HFALP improved the machining depth, mean deviation of the contour, and processing efficiency by 41.24%, 30.11%, and 3845.2%, respectively, and achieved stable fabrication of microchannel array structures with a profile deviation of only 0.1%. This study not only provides a reliable process for the thermal management application of AlN but also, through successful validation on other reactive materials, establishes a universal theoretical framework for “reactive medium-assisted laser processing”. This offers reusable technical pathways and mechanistic support for efficient and high-quality machining of various thermally-active materials.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"217 ","pages":"Article 104388"},"PeriodicalIF":18.8,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147502340","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Spatial heterostructure engineering and enhanced mechanical isotropy in hybrid additive manufacturing of high-strength aluminum alloys via different cyclic interlayer friction stir processing strategies","authors":"Jiming Lv ,&nbsp;Kaiyu Luo ,&nbsp;Haifei Lu ,&nbsp;Jinzhong Lu","doi":"10.1016/j.ijmachtools.2026.104389","DOIUrl":"10.1016/j.ijmachtools.2026.104389","url":null,"abstract":"<div><div>To address the dilemma between high-defect susceptibility of fusion-based additive manufacturing (AM) and the process-interruption sensitivity of solid-state AM for the high-strength AA7075 alloys, this study reports a hybrid manufacturing technology. It applies cyclic interlayer friction stir processing (C-IFSP) during laser directed energy deposition (LDED). The fundamental advancement lies in establishing a thermomechanical strategy that couples defect elimination and microstructural heterogeneity control, enabling in-situ architectural design of grain size and precipitate distributions across multiple length scales. Two contrasting C-IFSP strategies, unidirectional (UC-IFSP) and reciprocating (RC-IFSP), were systematically investigated. Both eliminated LDED-entrapped pores (porosity reduced by ∼4 and ∼7 orders of magnitude, respectively), but divergent thermomechanical transients yielded markedly different heterostructures: UC-IFSP produced laminated ultrafine/fine-grained layers along the build direction, whereas RC-IFSP established a bimodal grain structure with additional transverse heterogeneity. Consequently, RC-IFSP achieved synergetic enhancement of strength and ductility in the transverse direction while reducing strength anisotropy by 21.7%, reconstituting the strengthening mechanism from nanoprecipitate-dominated (wrought plate) to a synergistic strengthening of precipitate, dislocation, fine-grain, and heterogeneous deformation. This work establishes a pathway for defect-free, hierarchically controlled AM of high-strength Al alloys through spatially programmed thermomechanical processing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"217 ","pages":"Article 104389"},"PeriodicalIF":18.8,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147586813","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Thermal stress wave-driven regime in femtosecond laser-induced nanomaterial transfer revealed by ultrafast electron microscopy and atomic simulation","authors":"Yu Zhou ,&nbsp;Xiaoxiang Wang ,&nbsp;ZiJie Lu ,&nbsp;Guohu Luo ,&nbsp;Bin Chen ,&nbsp;Dongping Zhong ,&nbsp;Yongxiang Hu","doi":"10.1016/j.ijmachtools.2026.104366","DOIUrl":"10.1016/j.ijmachtools.2026.104366","url":null,"abstract":"<div><div>Femtosecond laser-induced transfer effectively prints plasmonic nanomaterials onto stretchable substrates. The transfer behaviors are precisely adjusted through laser fluence, distinguishing femtosecond laser processing from melt-driven or vapor-driven transfer processes. Since this transfer typically occurs at the nanoscale, elucidating its mechanism requires visualization with high spatiotemporal resolution. In this study, pulsed lasers are integrated with a transmission electron microscope for nanosecond- and nanometer-scale observations of transfer behaviors. The thermal stress wave-driven transfer regime is revealed through a two-temperature model coupled with molecular dynamics simulations. The irradiated nanoisland detaches and jumps away from the supporting substrate within tens of picoseconds, while its complete melting and contraction into spherical nanoparticles occur over several to tens of nanoseconds, marking the first nanoscale confirmation via experimental observation and atomic simulation. Ultrafast laser heating induces inhomogeneous lattice expansion, generating a gigapascal-level compressive thermal stress wave that propagates at the speed of sound. Upon reaching the interface, the compressive stress wave reflects as a tensile wave, leading to the detachment of nanoislands from the substrate. The process is primarily governed by directionally propagating normal stress waves rather than static thermal shear stress, with ultrafast non-equilibrium heating and constraints from the rigid substrate as crucial factors. This study reveals a novel thermal stress wave-driven regime in femtosecond laser-induced nanomaterials transfer, offering an effective approach for fabricating nano-plasmonic devices. These insights into thermo-mechanical coupling carry significant implications for advancing broader femtosecond laser micro/nano-processing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"216 ","pages":"Article 104366"},"PeriodicalIF":18.8,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145995520","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Printing mechanisms to support the supports: A dual-scale heat dissipation framework governing printing process, heat transfer, and forming performance in laser powder bed fusion","authors":"Han Zhang,&nbsp;Dongdong Gu","doi":"10.1016/j.ijmachtools.2026.104375","DOIUrl":"10.1016/j.ijmachtools.2026.104375","url":null,"abstract":"<div><div>Inappropriate, empiricism- and trial-and-error-driven use of supports tends to cause high scrap rates, prolonged build cycles, and elevated post-processing costs, becoming a key bottleneck to the industrial deployment of laser powder bed fusion (LPBF). To address the lack of a generalizable physical basis for support design in LPBF, this study combines targeted experiments with multiphysics simulations to elucidate how support topology and parameters regulate thermal behavior, down-skin quality, and anchoring strength. This study reconceptualizes supports as active thermomechanical boundary conditions by establishing a new dual-scale heat dissipation framework, in which macroscale overall heat removal governs melt-pool solidification morphology and process stability, and microscale local heat removal at the overhang interface controls dross formation and interfacial defects. Within this framework, block supports (continuous line contacts) reduce dross thickness by ∼20–40 % at comparable contact area, owing to a more uniform distribution of support points. In contrast, cone supports (discrete point contacts) enhance overall heat dissipation, raising the effective heat transfer coefficient by ∼38 % and lowering the melt-pool depth-to-width ratio. Anchoring strength is governed by stress distribution, and block supports reach ∼260.8 MPa (∼47 % of bulk) while using ∼44.8 % less contact area than cones. This work introduces a generalizable dual-scale framework with two physics-based design parameters: contact area ratio governing macroscale thermal conduction and unit density controlling microscale melt-contact probability. These parameters unify processing quality, heat transfer, and mechanical anchoring within a quantifiable design space, enabling predictive optimization across support typologies, materials, and geometries, and providing the mechanistic foundation for functional support design. This work enables predictive support optimization across materials, scan strategies, and geometries, thereby could reduce trial-and-error efforts, lower post-processing burdens, and improve the manufacturability and consistency of complex components.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"216 ","pages":"Article 104375"},"PeriodicalIF":18.8,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146072473","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Robotic end-effectors for manufacturing: Recent developments and future research challenges","authors":"Abdelkhalick Mohammad ,&nbsp;Erhui Sun ,&nbsp;Junfu Zhou ,&nbsp;Guilin Yang ,&nbsp;Guolong Zhang ,&nbsp;Jokin Munoa ,&nbsp;Asier Barrios","doi":"10.1016/j.ijmachtools.2026.104367","DOIUrl":"10.1016/j.ijmachtools.2026.104367","url":null,"abstract":"<div><div>Industrial robots excel at replicating human movements, with robotic arms mimicking the human arm and end-effectors replicating the hand. While robot arm designs offer versatility, end-effectors, typically designed for specific tasks, lack this flexibility. Despite numerous review papers focusing on specific applications or aspects of robotic end-effectors -such as agriculture, surgery, space, grinding, or control methods - a clear gap remains: the lack of a comprehensive review that integrates design, modeling, and control across diverse manufacturing applications. This paper reviews the state-of-the-art in robotic end-effectors, exploring their design variations and the enabling technologies that power them. The review categorises end-effectors based on their applications, including finishing, machining (traditional and non-traditional), additive manufacturing and grasping end-effectors. In each category we highlight the key design considerations for optimal performance. Beyond their application-specific designs, the paper explores the enabling technologies that shape end-effector capabilities. Sensors, the “eyes and ears,” provide crucial information on the environment through force sensors and vision systems. Actuators, the “muscles,” convert electrical signals into movement using pneumatics, hydraulics, or increasingly popular electric mechanisms. The paper concludes by discussing the modelling and control aspects of end-effectors. Kinematic, dynamic, and stiffness models are explored as crucial tools for designing and analysing these versatile tools, ensuring optimal functionality, accuracy, and efficiency. Finally, control tools act as the conductor, orchestrating the entire operation, and translating commands into real-time actions. This review emphasizes the importance of end-effectors in expanding robot capabilities and highlights the intricate interplay of design and enabling technologies that drive their development.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"216 ","pages":"Article 104367"},"PeriodicalIF":18.8,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145995514","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Nonlinear dynamic modeling of trochoidal milling with engagement loss-induced time-varying delay","authors":"Yuwen Sun ,&nbsp;Zhaoliang Li ,&nbsp;Jinbo Niu ,&nbsp;Shuoxue Sun ,&nbsp;Jinting Xu","doi":"10.1016/j.ijmachtools.2026.104377","DOIUrl":"10.1016/j.ijmachtools.2026.104377","url":null,"abstract":"<div><div>Engagement loss is a geometric-temporal switching mechanism that renders the chip thickness evolution nonsmooth and the delay state dependent and time-varying, thereby acting as a system nonlinearity. However, prior research has predominantly relied on regenerative chatter theory while neglecting the effect of cutter-workpiece engagement loss, resulting in inaccurate dynamic models for trochoidal milling. This paper develops a precise dynamic model for trochoidal milling that incorporates engagement loss effects and enables analysis of process nonlinear dynamics. First, the characteristics of the double trochoidal path are analyzed, and the mechanism by which engagement loss arises during milling is elucidated. On the basis of the above analysis, a novel numerical method is proposed to accurately calculate engagement loss rate resulting from variations in cutter-workpiece engagement conditions. Subsequently, a nonlinear dynamic model for trochoidal milling is developed using a time-domain simulation approach, which incorporates both time-varying delay and engagement loss effects. An adaptive prediction time-domain algorithm is then introduced, utilizing slope guidance to iteratively predict the initial axial depth of cut. The algorithm significantly narrows the search range for stability boundaries and enhances computational efficiency. Finally, the proposed model is validated through horizontal spiral and trochoidal milling experiments and compared with classical stability predictions. Results indicate that engagement loss reduces the overlap of regenerative waviness and modulates the effective delay, which weakens or intermittently breaks the regenerative loop and thereby raises the stability limit. The proposed time-varying mixed-delay dynamic model predicts milling stability with high accuracy.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"216 ","pages":"Article 104377"},"PeriodicalIF":18.8,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146160875","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Nanocutting mechanism of multi-layered metallic nanowires","authors":"Yuting Ye ,&nbsp;Huan Liu ,&nbsp;Yongda Yan ,&nbsp;Yanquan Geng","doi":"10.1016/j.ijmachtools.2026.104376","DOIUrl":"10.1016/j.ijmachtools.2026.104376","url":null,"abstract":"<div><div>Structural precision is a pivotal determinant of the performance and reliability of nanodevices, and achieving high-precision fabrication is the core objective of the nanofabrication field. Nanocutting opens up novel avenues for constructing intricate nanostructures, exhibiting extensive application prospects. However, the micro-deformation behaviour during this process is characterized by strong coupling of multi-scale and multi-mechanism features, and its formation and evolution mechanisms remain insufficiently elucidated. In particular, the impact of strain rate on the stress distributions at heterogeneous interfaces and the cooperative deformation mechanism still lack systematic investigation. In this study, Au/Ag/Au nanowires are employed as the research subject, to systematically reveal the influence mechanisms of cutting direction and strain rate on atomic-scale evolution behaviours. The results indicate that morphological evolution is dominated by anisotropic constraint mechanisms, and that the cutting orientation directly dictates the variations in stress-release pathways. Under high strain rates, the stress distribution within the Ag layer becomes significantly non-uniform, triggering crack initiation at the Au/Ag interface and leading to pronounced strain localization. Concurrently, interlayer atomic migration manifests as a thermo-mechanical-defect-coupled driving process, in which strain-rate-induced dislocations serve as high-speed “pipe diffusion” channels. This research systematically clarifies the intrinsic correlation between the instability behaviour and interlayer diffusion in multi-layer metal systems under high strain rates, providing a theoretical foundation for the deterministic machining of nanostructures.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"216 ","pages":"Article 104376"},"PeriodicalIF":18.8,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146152942","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Online time-optimal trajectory planning along parametric toolpaths with strict constraint satisfaction and certifiable feasibility guarantee","authors":"Yunan Wang,&nbsp;Chuxiong Hu,&nbsp;Yuanshenglong Li,&nbsp;Jichuan Yu,&nbsp;Jizhou Yan,&nbsp;Yixuan Liang,&nbsp;Zhao Jin","doi":"10.1016/j.ijmachtools.2025.104355","DOIUrl":"10.1016/j.ijmachtools.2025.104355","url":null,"abstract":"<div><div>As a fundamental technique in computer numerical control (CNC) machining, time-optimal trajectory planning (TOTP) is crucial for enhancing machining efficiency, geometric accuracy, and surface quality. However, it remains challenging to reliably generate smooth time-optimal trajectories online, particularly under complex constraints. This study aims to address the above longstanding challenges which limit the reliability and efficiency of online optimization-based TOTP approaches, thereby unlocking their practical advantages in real-world machining. A TOTP method along parametric toolpaths, namely TOTP-SPLP, is developed. The proposed piecewise linear objective function and sequential procedure improve time-optimality and avoid singularities at zero feedrate compared with existing linear formulations. Complex constraints are strictly satisfied at grid points over the entire toolpath without relying on static approximations, where exceedance between grid points is negligible and theoretically bounded by the grid density based on the developed analytical interpolation. To certifiably guarantee the feasibility during online TOTP, a hierarchical look-ahead windowing (HLAW) framework is established, which achieves a 100% success rate of optimization feasibility for long toolpaths. Simulation and real-world experiments demonstrate that the proposed TOTP-SPLP significantly outperforms existing online TOTP baselines in terms of time-optimality and numerical stability within limited computational cost. Specifically, TOTP-SPLP reduces terminal time by 15.6%–56.0% compared with baselines of lower computational cost, and outperforms more computationally expensive baselines by 9.5%. Comparable performance to our TOTP-SPLP is achieved by offline baselines only when consuming tenfold computational time. For a long toolpath with millions of grid points, the developed HLAW reduces the thousands of infeasibility cases encountered by existing online framework to zero. The strict satisfaction of complex constraints helps suppress vibrations and improve surface quality in real-world machining. In summary, this work fundamentally advances online TOTP by achieving offline-level time-optimality with certifiable feasibility under strict complex constraints, making reliable online optimization-based TOTP possible and practical in CNC machining.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"215 ","pages":"Article 104355"},"PeriodicalIF":18.8,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145784998","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}