Virtual Five-Axis Milling Machine: Tool Path Generation and Simulation

This paper presents the algorithms to generate and simulate non-linear tool path of the five-axis milling machine. The simulator is based on rD representation and employs an inverse kinematics approach to derive the corresponding rotational and translation movement of the mechanism. The simulator makes it possible to analyze an accuracy of a 3D tool path based on a prescribed set of the cutter location (CL) points as well as a set of the cutter contact (CC) points and the tool inclination angle. The resulting trajectory of the tool path is not unique and depends on the initial set up of the machine which in turn is problem dependent. Furthermore, the simulator can be used to simulate the milling process, verif, the final cut and estimate the errors of the actual tool path before the real workpiece is actually cut with the real machine. Thus, it reduces the cost of iterative trial and error. Tool path generation and simulation is verified by a series of cutting experiments performed by means of the proposed software and the accuracy of milling is estimated. It has been shown that the proposed graphical 3D software presents an efficient interactive approach to the modification of a tool path based on an appropriate set of transformations as well as verification of the tool path optimization algorithms. The result of the simulation has been tested using the Maho600E S-Axis Milling Machin