Custom post-processor based on the PSO algorithm for 5 axis machine tool compensation

This study presents an innovative geometric error compensation methodology for 5-axis CNC machines utilizing a meta-heuristic PSO algorithm. This approach focuses on post-processing trajectory paths utilizing the machine's inverse kinematic model, taking into account both machine geometric errors and the influence of CAD/CAM software during the design phase. This results in a multi-objective optimization problem that integrates collision and interference avoidance between the tool and the workpiece while compensating for the non-linear machine errors in order to make the actual tool path to be as close as possible to the CAM-designed. Moreover, this comprehensive analysis of different error sources contributes to a better understanding of their implications on machining precision and allows exploring alternative tool paths that improve the motion profile for 5-axis machines. Finally, this framework has potential for future expansion to accommodate more complex workpiece geometries through enhanced 3D contact detection algorithms or even estimating surface topography.