Pii: S0010-4485(00)00063-4

This paper presents a method of determining the shape of the surface swept by a tool that follows a 5-axis tool path for machining curved surfaces. The method consists of discretising the tool into pseudo-inserts and identifying imprint points using a modi®ed principle of silhouettes. An imprint point exists for each pseudo-insert and the piecewise linear curve connecting them forms an imprint curve for one tool position. A collection of imprint curves is joined to approximate the swept surface. This method is simple to implement and executes rapidly. The method has been veri®ed by comparing predicted results of a 3-axis tool path with analytical results and predicted results of a 5axis tool path with measurements of a part made with the same tool path. q 2000 Elsevier Science Ltd. All rights reserved.