Optimal tool orientation in 3 + 2-axis machining considering machine kinematics

In 5-axis machining, the initial orientation and position of the part in the fixture on the machine table are chosen to avoid collisions and to ensure that axes ranges are respected. However, kinematics of the machine is rarely considered for workpiece setup optimization although it affects the tool path execution and machining time. Indeed, for complex surfaces, actual feedrate is often lower than the programmed one and can present strong slowdowns, which are critical for the tool cutting conditions and therefore the part quality. This article investigates the use of kinematic manipulability criteria to determine the best orientation of the workpiece setup to maximize the actual feedrate and reduce machining time. The modelling of maximum velocity, acceleration, and jerk of each axis by means of polytopes makes it possible to take advantage of the whole kinematic space of the machine more intuitively. Simulations and experiments are carried out in 3 + 2-axis machining on test parts with a ball-end tool. For stretched surfaces, while the tool centre motion is given by the machining strategy, the tool axis orientation is optimized jointly with the workpiece setup. Experiments confirm that actual feedrate raises faster to better respect the programmed cutting conditions along each path. As feedrate is also higher, machining time is reduced significantly.