General 5-axis Machine Tool Modeling

RESEARCH

Course: Intelligent Optimization Course

Professor: CHEN Youdong

Prepared by: Mlungisi MANKANI ( 曼卡尼 )

Student ID: LS2407205

Date: 2025/07/21

北航无损检测与机电工程研究室 http:\\ndte.buaa.edu.cn 1
 Contents

01 Introduction

02 Motivation and Background

03 Research Objective

04 Method Overview and Literature Review

05 References

2
Introduction
Inverse Kinematics in Robotics
Introduction to 5-Axis Machines

Inverse kinematics (IK)

determines the joint
parameters needed to
achieve a desired end-
effector position and
orientation. It is essential for
precise tool path planning in
5-axis machines.

5-axis machines are advanced CNC systems capable of

moving a tool or part along five different axes
simultaneously, enabling the creation of complex shapes and
achieving high precision in manufacturing. They are widely
used in the aerospace, automotive, and medical industries. 3
Introduction
Advantages of 5-Axis CNC Machining
• Five-axis CNC machining offers unparalleled precision for fabricating complex designs – something
traditional machining methods cannot match, thus producing higher quality parts with reduced need for
rework and producing higher investment returns.
• Five-axis machine tools offer another significant benefit: efficiency. By moving simultaneously on
multiple axes, these machine tools can quickly complete complex operations while minimizing errors
during part processing, saving both time and labor costs in the process.
• Flexibility is another significant advantage. Manufacturers no longer face restrictions imposed by
toolpaths or machine limitations that prohibit processing different materials and shapes, opening up more
opportunities for innovation.
• Five-axis machining improves surface finish quality by approaching the workpiece from multiple angles,
thus minimizing machining marks and increasing aesthetic appeal, an advantage particularly valuable in
industries with demanding visual standards.

4
Introduction
Significance of Inverse Kinematics

1.Tool Position and Orientation Control

2.Machine Kinematics Optimization
3.Real-Time Control
4.Avoiding Unnecessary Axis Movements
5.Versatility Across Machine Configurations
6.Foundation for Simulation and Verification,
e.g. Vericut

Jacobian Matrices in Motion Control:

 Relate joint velocities to end-effector velocities
Key components of 5-axis machining:  Used for velocity and force analysis
I. Three linear axes (X, Y, Z)
II. Two rotational axes (A, B or C)
III. Enhanced flexibility and reach
5
Motivation and Background
Applications of 5-Axis
Machining
Aerospace Medical Industry
Industry

The aerospace sector relies heavily

Medical device manufacturing demands
on 5-axis machining for components
biocompatibility, precision, and smooth
with complex geometries and tight
finishes, making 5-axis machining
tolerances.
essential

6
Motivation and Background
Applications of 5-Axis
Machining
Automotive Mold and Die
Industry Manufacturing

5-axis machining supports high-volume Mold and die production benefits significantly
production of complex automotive from 5-axis machining due to the need for
parts, improving efficiency and quality. complex contours and high precision.

7
Research Objective

Comparison: Analytical vs. Numerical

 Analytical: Fast, exact, but limited to simpler machine tools or robots.
 Numerical: Flexible, handles complex robots, but slower machine tools or robots

Analytical Approach: IK, DH, and Jacobian Numerical Approach: IK, DH, and Jacobian
1. Derive closed-form equations for joint angles. 1. Iterative algorithms (e.g., Newton-Raphson, Gradient
2. Use DH parameters for transformation matrices Descent)
3. Compute Jacobian analytically for velocity 2. Numerically update joint values to minimize error
mapping 3. Jacobian used for iterative updates

8
Method Overview
Analytical Approach
Deriving Closed-Form IK
Equations
Goal: Derive closed-form expressions for joint variables (linear and rotary)
given any desired end-effector pose.
Given the tool tip position P = [Px, Py, Pz] and Tool Position Equations:
orientation V = [Vx, Vy, Vz] X = Px + L.sin β
Y = Py
Tool Orientation Equations: Z = Pz + L.cos β
β​= arccos(−Vz​) • L: Tool length (pivot-to-tip).
Γ = atan2(−Vy​,−Vx​)​
Where; Implementation
 β: B-axis tilt (arccos range [0,π][0,π]).
 γ: C-axis rotation (atan2 handles quadrants). • Code in MATLAB to
compute (X,Y,Z,B,C)
 Singularity Handling: If sinβ≈0 (vertical tool),
from (P,V).
set γ=0γ=0.

9
Method Overview
Numerical Approach
Concept

Using iterative optimization (e.g., Jacobian-based methods) to minimize the error

between the target tool pose and the forward-kinematics (FK) output for candidate axis
positions. This avoids deriving closed-form equations.
Algorithm: Jacobian Transpose Method

1. Defining FK Function: Computing tool pose [Pcalc, Vcalc] from axis positions θ =[X, Y, Z, A, B].

2. Error Function: Computing the difference between the target pose (Ptarget​, Vtarget​) and the FK
output.

3. Computing Jacobian Matrix J: Partial derivatives of F w.r.t. θ:

10
Method Overview
3. Iterating Until Convergence:
θk+1=θk+J−1⋅(Ttarget −F(θk))
Where;
• Ttarget=[P,V] is the Target pose.
• Termination: When error <ϵ (e.g., 10−6 mm/rad)
Implementation: Using MATLAB.
Verification/Validation in Vericut

Goal: Compare accuracy, computation time, and robustness of both

approaches.
Steps

1.Model Setup in Vericut:

1. Create machine with exact kinematics (e.g., linear axes X/Y/Z, rotary B/C).
2. Define tool geometry (length LL).
3. Add workpiece and coordinate systems (MCS/WCS).
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Method Overview
2. Test Cases:
1.Variety: Including non-singular poses, singularity (β=0), and extreme
orientations.
2.Metrics:
1.Position/orientation error (distance between actual/desired tool-tip).
2.Computation time for each method.
3.Iteration count (numerical method).
3. Procedure: Step 1: Computing axis values (X, Y, Z, B, C) using both methods for each test pose.
Step 2: Running Vericut simulation for each set of axis commands:
Using G-code (e.g., G01 X Y Z B C)
Enabling "Measure Point" to record the actual tool-tip position.
Using "Tool Axis Vector" output for orientation.
Step 3: Comparing results:
Position Error: ∥Pvericut−Ptarget∥.
Orientation Error: cos−1(Vvericut​⋅Vtarget​).
Computation Time: Profile code execution.
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Method Overview
Vericut
Simulation
• Loading G-code for both methods.
• Using "Auto-Diff" to compare tool paths.
• Generating "Inspection Report" for errors.

Results Interpretation:

Comparison of Analytical and Numerical in the

following metrics:

1. Position Error

2. Computation Time

3. Robustness

4. Generality (Deciding which one works for general machine)

13
Method Overview
Vericut
Workflow

Analytical IK G-Code

Target Vericut
Error Metrics Report Analysis
pose Simulation

Numerical IK G-Code

Goal: Comparing Vericut's measured tool poses against the target, we

objectively determine which method is more accurate and robust for a specific
machine configuration

14
Method Overview
Review of Literature

Key Aspects from the paper

This paper presents a generic five-axis
postprocessor system for various five-
axis machine tools. The generalized
kinematics model of common five-axis
machines is constructed by combining
two rotational degrees of freedom on
the fixture table and two rotational
degrees of freedom on the spindle.

Importance of the study

The complete analytical equations for NC data are obtained through
homogeneous coordinate transformation matrix and inverse kinematics. The
derived five-axis NC code expression is a general form suitable for all kinds
of five-axis machine tools with three orthogonal linear axes and two
orthogonal rotational axes. 15
 Method Overview
Review of Literature
Link and joint modeling

FULL TRANSFORMATION CHAIN

TO GET THE TOOL'S POSE IN THE WORKPIECE

COORDINATE FRAME:

Generalized five-axis machine tool with

four rotational degrees of freedom.

16
Method Overview
Review of Literature
General joint angle solutions for spindle-tilting type machine tool

17
Method Overview
Review of Literature

Analytical Methods and Error Key Aspects from the paper

Compensation • Introduces a streamlined analytical
approach to IK-based geometric error
compensation for non-orthogonal 5-
axis machine tools.
• Using homogeneous transformation matrices, the
authors derive closed-form IK and error
compensation equations, allowing direct
computation of correction NC codes from
Importance of the study analytical relationships.

This provides a strong reference for the

formulation of explicit, DH parameter-based
analytical IK and its real-world applications to
accuracy improvement and virtual machining.

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Method Overview
Review of Literature

Key Aspects from the paper

• Demonstrates a comprehensive
analytical treatment of both
inverse and forward kinematics for
a 5-axis hybrid manipulator.
• Discusses design constraints and workspace
analysis, showing how closed-form
approaches provide insights into
manipulator capabilities and limitations.
Importance of the study
The study will draw from their method for
constructing closed-form solutions, as well as for
comparative workspace evaluation.

19
Method Overview
Review of Literature

Key Aspects from the paper

• This paper uses numeric algorithms
to minimize volumetric errors in
complex 5-axis kinematics.
• They use kinematic modeling foundations
common to both approaches and show how
iterative optimization can address complex
error profiles where analytical solutions may
Importance of the study not exist.

Their verification through simulation aligns with

our strategy of validating both analytical and
numerical results virtually, rather than by
physical experimentation.

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Method Overview
Review of Literature

Key Aspects from the paper

The paper frames the IK problem for

automation and machining as a
numerical optimization, combining
target pose accuracy with motion
efficiency.
Importance of the study
The paper clearly shows the strengths of numerical methods in handling joint
constraints, efficiency trade-offs, and convergence, themes central to our planned
numerical IK implementation.

21
Method Overview
Review of Literature

Key Aspects from the paper

This article introduces a speedup

method for analytical and numerical
methods, which can improve their
performance.

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 References
[1] A. Antonov, A. Fomin, V. Glazunov, S. Kiselev, and G. Carbone, “Inverse and forward kinematics and workspace
analysis of a novel 5- DOF (3T2R) parallel–serial (hybrid) manipulator,” International Journal of Advanced
Robotic Systems, vol. 18, no. 2, 2021, doi: 10.1177/1729881421992963.

[2] Y.-L. Lai, C.-C. Liao, H.-Y. Chan, and C.-K. Su, “Inverse Kinematics of a Postprocessor for Five-Axis Machine Tools,”
2015.

[3] C. H. She and C. C. Chang, “Design of a generic five-axis postprocessor based on generalized kinematics model of
machine tool,” International Journal of Machine Tools and Manufacture, vol. 47, no. 3–4, pp. 537–545, Mar. 2007, doi:
10.1016/j.ijmachtools.2006.06.002.

[4] C. A. My et al., “Real Time Inverse Kinematics of Five-Axis CNC Centers.”

[5] W. Tian, W. Gao, W. Chang, and Y. Nie, “Error modeling and sensitivity analysis of a five-axis machine tool,”
Mathematical Problems in Engineering, vol. 2014, 2014, doi:10.1155/2014/745250.

[6] H. Cong, J. Zha, and Y. Chen, “Efficient compensation method of 5-axis machine tools based on a novel
representation of the volumetric error,” International Journal of Advanced Manufacturing Technology, vol. 126, no.
3–4, pp. 1109–1119, May 2023, doi: 10.1007/s00170-023-11117-6.

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Thanks
！