A novel five-axis cross-coupling control system that considers the motion and dynamic constraints of feed drive systems

This study presents an advanced cross-coupling control (CCC) system for five-axis machine tools that enhances contour accuracy during simultaneous machining. The method considers both the dynamic constraints of feed drive and the intricate kinematic relationships between the workpiece coordinate system (WCS) and the machine coordinate system (MCS). The method ensures precise control of tool trajectories and orientations by calculating compensation vectors for both the translational and rotational axes. These dynamically respect the constraints of each feed drive when minimizing contour and orientation errors. In contrast to recent works that sought to improve contour accuracy, our approach reduces any need for complex mathematical modeling, facilitating immediate integration with various computerized numerical control (CNC) machine tool configurations. Experimentally, machining contour accuracy and surface quality improved; the method is very precise. Again, the method can be seamlessly integrated with existing CNC machine tools; this ensures immediate industrial applications.