Direct cutting of a pyramid part to evaluate a five-axis machine tool with the Taguchi method

When evaluating five-axis machine tools, to develop a simple method is easy to implement for the many real unpreventable issues that occur, such as during part assembly, machining vibration, and finding a way to compare different machine tool types. A traditional verification assessment cannot overcome these issues. The implementation method for the test piece is not limited to any specific geometric cutting pattern, and these test pieces should not be limited only to a certain type of five-axis machining. In this paper, we used a pyramid test piece for the direct cutting verification comparison. By using different test piece processing and different crossed-axis five-axis machine tools, it is difficult to determine the characteristic points of machining errors, which is why we proposed a direct cutting method. From the results, we prove that the pyramid test piece is a simple one-time use method to quantify the comparison data from a single rotary axis. To calculate the cutting motion error data from the corresponding direct cutting motion, we will use mechanical advantage (MA) along with Taguchi’s method for signal-to-noise (S/N) ratio. In addition, in order to solve the interactive effect of multi-axis motion, we also proposed using Taguchi’s “variable separable model” to quantify the interaction value of each cutting motion, which solves this evaluation question.