Five-Axis Tool Path Optimization Using Rotations and Orientation

This paper presents the algorithms to interactively optimize the tool path of the five-axis milling machine. The algorithms employ the inverse kinematics to derive the corresponding trajectories (rotation and translation movement) of the five-axis machine. The trajectory of the tool path is not unique and depends on the initial set up of the workpiece as well as the combined rotations of the machine rotary axes. The proposed methods interactively select the appropriate workpiece orientation with the combination of rotations. The resulting optimized tool path can be used to simulate the milling process, verify the final cut and estimate the errors of the actual tool path before the real machining. It has been shown that the interactive approach provides an efficient way to the modification of a tool path based on an appropriate set of rotations and the initial workpiece orientation. Tool path optimization is verified by computer simulation software developed by the author as well as by real cutting on MAHO600E five-axis machine.