Abstract Corner rounding methods have been widely developed to pursue the smooth motions of machine tools. However, most corner rounding methods, which adopt the double inscribed transitions, still remain an inherent issue of retaining large curvatures of transition curves. Even for those double circumscribed transitions-based methods with relatively small curvatures, they also constrain excessively the transition lengths and are limited to a low-order continuity, deteriorating the feedrate and jerk of machine tools. For addressing these problems, a C3 continuous double circumscribed corner rounding (DCCR) method is proposed for five-axis linear tool path. In this method, the C3 continuous double circumscribed B-splines are specially designed to round the corners of tool position and tool orientation, whose transition lengths are analytically determined by jointly constraining the approximation errors, overlaps elimination, and parameter synchronization. Moreover, the excessive constrains of transition lengths imposed by traditional methods are alleviated by fully considering the effects of overlaps and parameter synchronization, and the jerk of rotary axes is also limited with a high-order continuity. Compared to the existing double inscribed corner rounding (DICR) and DCCR methods, experiment results demonstrate that our method can improve further the feedrate while limiting the jerk of machine tools.

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