The optimization of the tool trajectory of 5-axis milling still presents a considerable challenge, though current CAM systems not only generate NC programs but also include functionalities of the cutting simulation. The reason comes from the fact that commercially available cutting simulators focus on only avoiding collisions among the machined part, the machine tool and the cutting tool. The tool trajectory should be optimized with regard to the geometrical constraints and the dynamics of the process such as the cutting force, the tool deflection and the machine tool vibration. Li this study, in order to analyze the relationship between the tool posture and the cut surface roughness, a support system for 5-axis ball end milling to analyze machined surfaces was developed and fundamental cutting experiments were conducted. The experimental results of the surface roughness measurements are compared with the computed geometry of the cut surface to be obtained by the developed simulator.
