Tool path simulation using a virtual 5-axis milling machine

Presents the algorithms to simulate nonlinear kinematics of a 5-axis milling machine. The simulator is based on 3D representation and employing the inverse kinematics approach to derive the corresponding rotational and translation movement of the mechanism. The simulator makes it possible to analyze the 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 with tool inclination angle. The resulting trajectory of the tool 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, verify the final cut and estimate the errors of the actual tool-path before the real workpiece is actually being tested with the real machine. Thus, reducing the cost of iterative trial and error. Tool path simulation is verified by a series of cutting experiments performed by means of the proposed software and evaluates the accuracy of milling. It has been shown that the proposed graphical 3D software presents an efficient interactive approach to the interactive modification of a tool path based on an appropriate set of transformations as well as to verification of the tool path optimization algorithms.