A new accurate curvature matching and optimal tool based five-axis machining algorithm

Free-form surfaces are widely used in CAD systems to describe the part surface. Today, the most advanced machining of free from surfaces is done in five-axis machining using a flat end mill cutter. However, five-axis machining requires complex algorithms for gouging avoidance, collision detection and powerful computer-aided manufacturing (CAM) systems to support various operations. An accurate and efficient method is proposed for five-axis CNC machining of free-form surfaces. The proposed algorithm selects the best tool and plans the toolpath autonomously using curvature matching and integrated inverse kinematics of the machine tool. The new algorithm uses the real cutter contact toolpath generated by the inverse kinematics and not the linearized piecewise real cutter location toolpath.