Development of Post-Processing System for Three Types of Five-Axis Machine Tools Based on Solid Model

Although machine control data can be obtained by means of converting cutter location (CL) data comprised of the tool tip coordinate and the tool axis orientation vector in the workpiece coordinate frame with postprocessor, it’s uncertain whether they can be used for 5-axis machining. Owing to the fact that most postprocessors focus on the method to derive solutions for the equations of NC data by the form-shaping function matrix and the inverse kinematics model without taking the manufacturing scene into consideration, this study has presented a new post-processing system to generate and optimize NC data more effectively by correcting and selecting optimum solution intelligently for machining based on the solid model of machine tool in simulation environment. In general, the post-processing system consists of user interface layer, data access layer and data processing layer to give expression to the characteristics of universality, practicality and adaptability. User interface layer is mainly about loading the machine model and setting the relevant parameters. Data access layer includes model library of generalized five-axis machine tool configurations, rules library of cutter location data and NC data. Data processing layer is the major research in the paper, which illustrates how to correct the inverse solutions set and select the optimization solution for actual machining. The visual interface for post-processing system written by C++ was successfully applied in the experiment on a five-axis machine tool with a C-axis behind a B-axis rotary table, which demonstrated the effectiveness of the proposed post-processing methodology in the field of manufacturing.