The look-ahead based adaptive motion control for high-speed machining of complicated contours

The contour of a special part commonly consists of line and arc segments (non-micro segments), as well as continuous micro line segments (micro segment groups) that precisely approach the complicated or irregular portions of that contour. For precise machining of the contour, especially for those complicated or irregular portions, the real-time generation of motion command for X and Y axes should be decided according to the characteristics of the contour. Thus, in this paper, a look-ahead based adaptive motion control algorithm is presented. The structure of the whole motion control algorithm is analyzed at first, which guarantees real-time machining. In addition, concrete adaptive motion control algorithms for both non-micro segments and micro segment groups are elaborated. The motion control algorithm predicts the variation of the curvature of the coming trajectory so that adaptively determining whether to accelerates feedrate to enhance machining efficiency or decelerates the feedrate to guarantee machining precision. Finally, both simulation results and experimental results are presented to verify the efficiency of the proposed motion control algorithm.