Research on look ahead control of contour error for casting sand mold with five-axis linkage high speed machining

Casting sand mold with five-axis linkage high speed machining has the characteristics of high feeding speed, small milling force, fast tool axis swing speed and big contour error. The coupling relationships among tool axis swing, following error and contour error were analyzed, the computing method of axis movement speed for five-axis linkage machining was proposed, and a rapid linear estimation model of contour error for casting sand mold with five-axis linkage machining was established. On this basis, according to the relationships between rotary axis speed and tool axis swing speed, a look ahead self-adaptive control method of contour error for casting sand mold with five-axis linkage high speed machining was proposed, and an experiment of impeller sand mold with five-axis linkage machining was carried out. The results show that the contour error formed by tool tip can be estimated rapidly according to the tool axis swing speed in the process of casting sand mold with five-axis linkage high speed machining, and the proposed look ahead control of the rotary axis speed is an effective method for contour precision of casting sand mold with five-axis linkage high speed machining.