The discontinuities of a five-axis linear-segment toolpath result in fluctuation in the feedrate, acceleration and jerk commands that lead to machine tool vibration and poor surface finish. For path smoothing, with the global curve-fitting method it is difficult to control fitting error and the local corner-smoothing method has large curvature extreme. For path synchronization, the parameter synchronization method cannot ensure smooth rotary motion. Aiming at these problems, this paper proposes a double B-spline curve-fitting and synchronization-integrated feedrate scheduling method. Two C2-continuous and error-bounded B-spline curves are produced to fit tool-tip position and tool orientation, respectively. The fitting error is controlled by locally refining the curve segments that exceed the fitting tolerance. The tool-tip position trajectory is firstly planned to address axial kinematic constraints in the feedrate scheduling process. Then the feedrate is deformed for the tool orientation to guarantee smooth rotary motion as well as to share the same motion time with the tool-tip position segment by segment. The feasibility and effectiveness of the proposed method have been validated by simulations and experiments on the S-shape test piece. Simulations show that the proposed curve-fitting method can generate smooth toolpath and constrain fitting error. The proposed feedrate scheduling method can guarantee smooth rotary motion and keep axial motions under kinematic limits, compared with the method that does not consider axial kinematic constraints and the parameter synchronization method. Experimental results verify that the proposed curve-fitting method can generate smooth tool path under fitting tolerance, and the proposed feedrate scheduling method can produce smooth and restricted axial motions.
