Virtual verification of 5-axis machine tools based on workpiece accuracy analysis: Software tool instead of expensive machining tests

An approach to predict the workpiece accuracy in 5-axis machining based on the standard acceptance conditions for machining centers (ISO 230-1) is introduced. The end-user should be able to verify the machine tool accuracy performances in advanced to the purchasing stage and prevent false buying decisions as well as non-relevant expensive machining tests. The preparatory testing of the machine may be not sufficient for the machine tool end-user to define the machining accuracy boundaries of complex parts. To set the machining process providing the required part accuracy, software interface "machine accuracy-machined part accuracy" is developed. The software combines data bases of machines and typical parts connected by virtual machining processes. As a mathematical tool, the modified form-shaping function is applied. The modification enables simulation of multi-tasking machining accuracy. Experimental testing is carried out to validate the effectiveness of the proposed approach.