Tool path planning and simulation for five-axis machining test

Five-axis machining has a wide range of applications, in fields such as the aerospace and automobile industries and the fabrication of turbine blades. Although five-axis machine tools are capable of meeting industrial demands for geometric variety and high precision, the additional rotary axes lead to an increased number of error terms. Evaluating the precision of machine tools is an issue of considerable importance; however the process can be complex and time-consuming, particularly for five-axis machining. A high degree of accuracy is required both in evaluating the processing of test pieces and in rectifying errors associated with machine tools. This paper presents a five-axis machining test, based on NAS 979 cutting path planning standards. A test piece with five-axis machining features is proposed. Cutter location data for the test piece was generated using a commercial CAD/CAM system (UG) and converted to five-axis NC code using a postprocessor created in UG Post Builder. Verification using VERICUT® solid cutting simulation software demonstrated the veracity of the generated five-axis NC code. The proposed machining test is applicable in a wide range of five-axis machine tool configurations; however, further testing with actual machining applications will be required for further verification.