Errors estimation and minimization for the 5-axis milling machine

This paper presents the tool path optimization algorithms to compute and estimate the non-linear inverse kinematics errors of the 5-axis milling machine. The approach is based on a global approximation of the required surface by a virtual surface constructed from the tool trajectories. Errors are computed from the difference between the required surface and the virtual surface and displayed numerically and graphically through the virtual machine simulator. 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 estimate the errors 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. Errors, particularly near the vicinity of the large milling errors, are minimized using a discrete algorithm based on a shortest path strategy. Furthermore, the simulator can be used to simulate the milling process, verify the final cut of the actual tool-path before testing with the real machine. Thus, it reduces the cost of iterative trial and errors.