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September 10, 2025Open Access

Flexible 5-Axis Machining with Toolpath Compensation Based on Workpiece Setting Error

DNDaisuke NaritaThe University of Tokyo ZRZongwei RenThe University of Tokyo HYHayato YoshiokaThe University of Tokyo

Key Points

The proposed method improves machining by calculating setting errors and adjusting the toolpath accordingly.
Measured setting errors during machining reduced need for resets, enhancing efficiency and reducing labor time.
By using a 3D scanner, setting errors can be detected without a traditional reference plane, facilitating complex geometries.
Validation through simultaneous 5-axis machining demonstrates the effectiveness of this error compensation method.

Abstract

Although near-net-shape machining offers significant advantages, it presents a notable challenge due to the complexity of the pre-finishing geometries. This complicates the workpiece setting during the finishing process. To address this problem, a measurable reference surface with a touch probe is typically employed. Furthermore, the workpiece is repeatedly reset until the setting error falls within the acceptable tolerance. Alternatively, a custom jig is designed and fabricated to mitigate setting errors. However, both approaches result in increased labor and extended time. Therefore, a novel method is proposed in this study wherein the setting position of a workpiece is measured using a 3D scanner. The setting error relative to the ideal setting position is calculated, and the toolpath is adjusted accordingly based on this error. This proposed method facilitates machining without the need for resetting, including when errors occur during the setting of workpieces that lack a reference plane or have intricate geometries. Moreover, the effectiveness of the proposed method was validated through simultaneous 5-axis machining utilizing the setting error compensation method.

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