5-axis CNC machining now is getting popular because it can deal with complex shapes such as impeller, turbine blade and propeller without additional equipment or process, proving a set of various tool orientations. CAM software related to 5-axis machining is being developed quickly so that users can take advantage of potential capacities of 5-axis machine tools. However, only a few researches can be found in the area of control strategy development for 5-axis machining. This paper proposes a 5-axis cross-coupling control system based on a novel tool orientation error model. The proposed tool orientation error model provides accurate information on the tool orientation error in real time, which in turn enables directly controlling the tool orientation accuracy. The proposed control system also employs a contour error model to calculate the contour error and reflect it in the control as well. The accuracy of the proposed tool orientation error model is verified and the performance of the 5-axis cross-coupling control system in terms of both contouring and tool orientation accuracy is evaluated through computer simulations compared with existing 5-axis control systems.
