Acceleration smoothing algorithm based on jounce limited for corner motion in high-speed machining

In high-speed and high precision machining, cornering acceleration profiles of the feed motion are always not smooth enough and cause severe inertial vibrations in feed drive system, which severely affect machining quality and elongate machining time. In view of this problem, many experts and scholars have proposed kinematic corner smoothing algorithms based on the jerk limited acceleration profile from the perspective of kinematics that generate continuous acceleration transition profiles. But continuous acceleration profiles still have non-differentiable points. In order to further generate smooth and continuous acceleration transition profiles, an acceleration smoothing algorithm based on the jounce limited acceleration profile is proposed in this paper. Firstly, by adding different velocity, acceleration, and displacement boundary conditions to the jounce limited acceleration profile and combined with user-specified contour error, the fastest cornering velocity is deduced. Next, by the fastest cornering velocity and motion performance of the motor driver, the cornering duration is deduced. Finally, smooth acceleration and velocity transition profiles can be controlled analytically by accurately calculating cornering duration. The proposed algorithms are divided into interrupted acceleration smoothing algorithm and uninterrupted acceleration smoothing algorithm based on additional different acceleration boundary conditions. Through the experimental analysis and comparison, the proposed algorithms can reduce overall machining time around 6–7% and deliver curvature smoothing motion profiles, curvature continuous velocity profiles, and tangent continuous acceleration profiles. The proposed algorithms achieve smooth acceleration transitions and improve machining quality.