Int J Adv Manuf Technol (2008) 38:728–740
DOI 10.1007/s00170-007-1126-5
ORIGINAL ARTICLE
Postprocessor development of a five-axis machine tool
with nutating head and table configuration
Chen-Hua She & Zhao-Tang Huang
Received: 21 August 2006 / Accepted: 7 June 2007 / Published online: 4 August 2007
# Springer-Verlag London Limited 2007
Abstract The postprocessor is an important interface that
transforms cutter location data into machine control data, and
in a five-axis machine tool is highly complex because the
simultaneous linear and rotary motions occur. Since most
works of the five-axis postprocessor method have dealt only
with the orthogonal machine tool’s configuration, this study
presents a postprocessor scheme for two types of five-axis
machine tools, each with a nutating head and a table whose
rotational axes are in an inclined plane. The benefit of such a
configuration is that it allows switching from vertical to
horizontal machining by a single machine. The general
analytical equations of NC data are obtained from the forward
and inverse kinematics and the homogeneous coordinate
transformation matrix. The linearization algorithm for the
postprocessor is developed to ensure the machining accuracy.
The presented algorithm is implemented using a window-based
five-axis postprocessor with nutating axes, and programmed in
Borland C++ Builder and OpenGL. A simulation is performed
using solid cutting software and a trial-cut experiment was
conducted on a five-axis machine tool with a nutating table to
elucidate the accuracy of the proposed scheme.
Keywords Postprocessor . Five-axis machining .
Form-shaping function . Nutating axis
C.-H. She (*)
Department of Mechanical and Computer Aided Engineering,
National Formosa University,
64 Wen-Hua Road, Huwei,
Yunlin 632, Taiwan, Republic of China
e-mail: chshe@nfu.edu.tw
Z.-T. Huang
Department of Mechanical and Automation Engineering,
Da-Yeh University,
112 Shan-Jiau Road, Da-Tsuen,
Chang-Hua 515, Taiwan, Republic of China
1 Introduction
Five-axis machining is becoming increasingly used by
machine tool users, especially in machining complex
freeform surfaces. The conventional five-axis machine tool
has three orthogonal linear axes and two rotary axes. The
rotary axes are typically orthogonal to each other and the
centre line of the rotary axis is parallel to the direction of
the linear axis. Various machine tool builders, such as
Makino, Ingersol and Deckel Maho, incorporate a nutating
head or a nutating table in the machine tools to improve
their versatility and flexibility. The word of “nutating”
means oscillatory motion about the axis of a rotating body,
which is similar to the slow spinning of a coin on a table. A
five-axis machine tool with a nutating unit has a rotational
axis in an inclined plane [1], and not parallel to the linear
axis, providing the advantage that allows the cutting tool to
orient itself toward any angle within a hemisphere [2, 3].
Such machines can move continuously between the
horizontal and vertical positions in a single setup on the
same machine. The nutating head provides very useful in
manufacturing aerospace parts because it has no motors on
the head, and is more rigid. The motors for the spindle are
on the machine and the motion is transferred to them by
hollow shafts and gears [4].
Because the linear and rotary axes move simultaneously
on a five-axis machine, the derivation of the five-axis
program is more complex than that of the three-axis
program. A postprocessor must be utilized to translate the
cutter location (CL) data from the CAM system into the
machine control data. Although the advanced controllers
can accept the CL data to machine the workpiece in real-
time without the need of postprocessor [5], they are
relatively expensive and not commonly used in most
industries. The methods of developing multi-axis postpro-
Int J Adv Manuf Technol (2008) 38:728–740
cessors can be mainly divided into three categories -
graphical [6], numerical iterative [7] and coordinate
transformational [8–10]. Since the coordinate transforma-
tion method yields the analytical equation of NC data most
efficiently, it has been adopted extensively in recent work.
However, almost all of these approaches involve postpro-
cessor methods for five-axis machine tools with orthogonal
rotary axes. Relatively few studies have addressed non-
orthogonal configuration. For example, the authors have
developed the postprocessor for the spindle-tilting type
five-axis machine tool with a nutating head [11]. Recently,
Sorby [12] has presented a closed-form solution for a table-
tilting type five-axis machine tool with a nutating table.
However, this solution exhibits some limitations. For
example, the offset vectors such as from the workpiece
origin to the rotary table and from the secondary rotary to
the primary rotary are not defined, and the angle of
inclination of the nonorthogonal axis is fixed at 45 degrees.
This study develops a postprocessor for two five-axis
machine tools each with a nutating head and table config-
uration. Based on the homogeneous coordinate transforma-
tion matrix, the general analytical equations of NC data are
obtained from the forward/inverse kinematics and the
machine tool’s form-shaping function matrix. The deter-
mined equation is in general form because the rotary axes are
assumed not to intersect each other; the angle of inclination
of the nonorthogonal axis is variable, and the offset vector
from the origin of the workpiece to the rotary table is
defined. Moreover, the linearization algorithm of the post-
processor is developed to ensure the machining accuracy.
A window-based postprocessor is developed and a graph-
ical interface that dynamically displays the surface model and
the motions of all of the axes of the configured machine tool is
presented to help the user to input relevant parameters
correctly. Additionally, the generated NC data are verified
using the commercial solid cutting software VERICUT® [13]
and a machining experiment is conducted on a five-axis
machine tool with a nutating table to confirm the effective-
ness of the proposed postprocessor methodology.
2 Configuration and modeling of five-axis machine tool
Most five-axis machine tools have two rotary axes as well
as the conventional X, Y and Z axes. Following Sakamoto
2 3
Wx2 Vφw þ Cφw Wx Wy Vφw
Wz Sφw
6 Wx Wy Vφw þ Wz Sφw Wy2 Vφw þ Cφw
RotðW; φw Þ ¼ 6
4 W W Vφ
W Sφ
x z w y w Wy Wz Vφw þ Wx Sφw
0 0
729
and Inasaki [14], the configurations of five-axis machine
tools can be categorized into three types: spindle-tilting,
table-tilting and table/spindle-tilting. Commercial machine
tools with the nonorthogonal configuration, as shown in
Fig. 1, are also of three types. Figure 1 (a) shows the
spindle-tilting type with a nutating head, such as the
Makino MAG3 [2], which is designed with a rotary axis
(C-axis) behind a nutating head that rotates about the B-
axis. Figure 1 (b) displays the table-tilting type with a
nutating table, such as the Deckel Maho DMU 70 eVolution
[15], which has two rotary axes on the table, and one rotary
axis (C-axis) is parallel to the Z-axis while the non-
orthogonal rotary axis is inclined at an angle to the C-axis.
Figure 1 (c) presents the table/spindle-tilting type with a
nutating head, such as the Deckel Maho 200P [15], in which
one rotary table (C-axis) is on the table and the nutating
rotary head (B-axis) is on the spindle. Since the authors have
already presented the spindle-tilting postprocessor with a
nutating head [11], this study focuses on developing the
postprocessors with the other two configurations.
A five-axis machine tools can be regarded as a
mechanism with serially connected links with revolute or
prismatic joints. Forward kinematic equations must be
established to describe mathematically the motion of the
cutting tool in relation to the workpiece. The fundamental
coordinate transformation matrices, including the transla-
tion matrix Trans and the rotation matrix Rot [16], are
introduced. The translation matrix Trans can be expressed
as follows:
2 3
1 0 0 a
60 1 0 b7
Transða; b; cÞ ¼ 6
40
7 ð1Þ
0 1 c5
0 0 0 1
where Trans(a, b, c) implies a translation given by the
vector a i+b j+c k.
The general rotation transformation matrix should be
used to describe the rotation of the nutating unit. The
coordinate system is assumed to rotate through an angle of
f w around any arbitrary vector W=Wx i+Wy j+Wz k; the
rotational transformation matrix can be expressed as:
Wx Wz Vφw þ Wy Sφw 0
Wy Wz Vφw
Wx Sφw 07
7 ð2Þ
Wz2 Vφw þ Cφw 05
0 1
730 Int J Adv Manuf Technol (2008) 38:728–740

ƒFig. 1 Configuration for five-axis machine tool with nutating head and
C
a table. a spindle-tilting type with a nutating head. b table-tilting type
with a nutating table. c table/spindle-tilting type with a nutating head

where “C” and “S” are cosine and sine functions,

respectively, and V f w =1–C f w.
B

Z 3 Postprocessor
Y X
3.1 Table-tilting type with a nutating table

Figure 2 depicts relevant coordinate systems for this

configuration. The coordinate system for the workpiece is
OwXwYwZw while the system OtXtYtZt is attached to the
cutting tool. Since the two rotary axes are assumed not to
intersect each other, a common normal line is mutually
perpendicular to both axes. The common normal line inter-
sects with the C-axis and B-axis at two points, RC and RB.
The offset vector Lx i+Ly j + Lz k is determined from the
b origin Ow to the pivot point RC, whereas the offset vector
Mx i+My j+Mz k is calculated from the pivot point RC to
the pivot point RB.
Since the structural elements of the machine tool
comprise the C rotary table, the B nutating rotary table,
the machine bed, the X linear table, the Y linear table, the Z
linear table, the spindle head and the cutting tool. The
C relative position and orientation of the cutting tool with
B respect to the workpiece can be determined sequentially
starting from the workpiece and ending at the cutting tool
Z and is referred to as the form-shaping function [17]. The
Y X

Zt
B Z

Y X Yt Xt
C
Ot
Zw
B Yw
C Xw
RB

RC Ow
Offset vector Offset vector
Mx i + M y j+ Mz k Lx i + Ly j + Lz k
Fig. 2 Coordinate systems of table-tilting type configuration
Int J Adv Manuf Technol (2008) 38:728–740 731

form-shaping function of this machine tool can be

mathematically expressed in matrix form as follows:

2 3
00



6 0 0 7
Trans Lx ; Ly ; Lz Rotðz;
φz ÞTrans Mx ; My ; Mz RotðW;
φw ÞTrans Px ; Py ; Pz 6
41 05
7 ð3Þ
01

where Px, Py and Pz denote the relative translation distances of Ky j þ Kz k are known, the CL data can be expressed in the
the X, Y and Z linear tables, respectively. The terms f z and matrix form as follows:
f w represent the angles of rotation for the C-axis and the B- 2 3
  Kx Qx
axis, respectively. The positive rotation is in the direction of an 6 Ky Qy 7
K Q
advancing right-hand screw about the +C and +B axes. ¼6 4 Kz Qz 5
7 ð4Þ
0 1
Equation (3) specifies the form-shaping function matrix of this 0 1
machine tool and the joint parameters Px, Py, Pz, f z and
f w should be determined by the inverse kinematics. The first Since both Eq. (3) and Eq. (4) represent the same
step is to calculate the required rotary angles to yield the tool relationship between the cutting tool and the workpiece, the
orientation, and the second is to calculate the required position desired joint parameters can be determined by equating
in relation to the linear axis to determine the position of the these two matrices. Equating the CL data matrix and the
centre of the tool tip using the known rotary angles. form-shaping function matrix, and taking the corresponding
When the CL data including the position of the centre of the elements of the two matrices yield the following equations:
tool tip Qx i þ Qy j þ Qz k and the tool orientation Kx i þ

2 3 2     3
Kx Cφz Wx Wz ð1
Cφw Þ
Wy Sφw þ Sφz Wy Wz ð1
Cφw Þ þ Wx Sφw 
6 Ky 7 6
Sφ Wx Wz ð1
Cφ Þ
Wy Sφ þ Cφ Wy Wz ð1
Cφ Þ þ Wx Sφ 7
6 7 ¼ 6 z w w z w w 7 ð5Þ
4 Kz 5 4 Wz2 ð1
Cφw Þ þ Cφw 5
0 0


2  2    3
Px Cφn z Wz ð1
Cφw Þ þ Cφw þ Sφz Wx Wy ðh1
Cφw Þ
Wz Sφw io
6 7
6 þPy Cφz Wx Wy ð1
Cφw Þ þ Wz Sφw þ Sφz Wy2 ð1
Cφw Þ þ Cφw 7
6 7
6 þP Cφ W W ð1
Cφ Þ
W Sφ  þ Sφ W W ð1
Cφ Þ þ W Sφ  7
6 z z x z w y w z y z w x w 7
6 þL þ Cφ M þ Sφ M 7
6 x z x z y 7
6 7
2 3 6  7
Qx 6 P
Sφ W 2 ð1
Cφ Þ þ Cφ  þ Cφ W W ð1
Cφ Þ
W Sφ  7
6 x n z x w w z x yh w z w io 7
6 Qy 7 6   7
6 7 ¼ 6 þPy
Sφz Wx Wy ð1
Cφw Þ þ Wz Sφw þ Cφz Wy2 ð1
Cφw Þ þ Cφw 7 ð6Þ
4 Qz 5 6      7
6 7
1 6 þPz
Sφz Wx Wz ð1
Cφw Þ
Wy Sφw þ Cφz Wy Wz ð1
Cφw Þ þ Wx Sφw 7
6 7
6 þLy
Sφz Mx þ Cφz My 7
6 7
6     7
6 7
6 Px W x Wz ð1
Cφw Þ þ Wy Sφ
 w þ Py Wy Wz ð1
Cφw Þ
Wx Sφw 7
6 7
6 þPz Wz2 ð1
Cφw Þ þ Cφw þ Lz þ Mz 7
4 5
1
732 Int J Adv Manuf Technol (2008) 38:728–740

The joint angles f z and f w should be determined first. If the operating range of the nutating table is in the range
Equating the corresponding third element in Eq. (5) yields between –π and 0, the solution should be modified as
the following B-axis angle: shown in Eq. (8). On the other hand, if the operating range

Kz
Wz2 of the nutating table meets the two possible solutions, the
B ¼ φw ¼ arccos 0  φw  π ð7Þ shortest rotational angle movement of the nutating table is
1
Wz2
usually chosen in the algorithm.
Notably, there is another possible solution for B-axis Furthermore, equating the corresponding first and
angle in the range of
π  φw  0, which can be obtained second elements in Eq. (5) and solving the simultaneous
as follows: linear equations for S f z and C f z, yield:

Kz
Wz2
B ¼ φw ¼
arccos ð8Þ
1
Wz2

   

Ky Wx Wz ð1
Cφw Þ
Wy Sφw þ Kx Wy Wz ð1
Cφw Þ þ Wx Sφw
Sφz ¼  2  2 ð9Þ
Wx Wz ð1
Cφw Þ
Wy Sφw þ Wy Wz ð1
Cφw Þ þ Wx Sφw

   
Kx Wx Wz ð1
Cφw Þ
Wy Sφw þ Ky Wy Wz ð1
Cφw Þ þ Wx Sφw
Cφz ¼  2  2 ð10Þ
Wx Wz ð1
Cφw Þ
Wy Sφw þ Wy Wz ð1
Cφw Þ þ Wx Sφw

Since the denominators in Eqs. (9) and (10) are the same
and always positive, the C- axis angle can be determined as
follows:

   
C ¼ φz ¼ arctan2ð
Ky Wx Wz ð1
Cφw Þ
Wy Sφw þ Kx Wy Wz ð1
Cφw Þ þ Wx Sφw ;
   
Kx Wx Wz ð1
Cφw Þ
Wy Sφw þKy Wy Wz ð1
Cφw Þ þ Wx Sφw Þ ð11Þ

π  φz  π

where arctan2(y,x) is the function that returns angles in the
range
p  q  p by examining the signs of both y and x
[16].
In addition, comparing the corresponding elements of
the matrix on both sides of Eq. (6) yields three simulta-
neous equations in three unknowns Px, Py and Pz. The
program coordinate system is assumed to coincide with the
workpiece coordinate system. Accordingly, the expressions
of the desired NC data (denoted as X, Y and Z) can be
obtained by considering the two offset vectors Lx i+Ly j+Lz
k and Mx i+My j+Mz k, and are expressed as follows:

X ¼ Px þ Lx þ Mx

    
¼ Qx
Cφz Mx þ Sφz My þ Lx Cφz Wx2 ð1
Cφw Þ þ Cφw þ Sφz Wx Wy ð1
Cφw Þ
Wz Sφw

     ð12Þ
þ Qy

Sφz Mx þ Cφz My þ Ly
Sφz Wx2 ð1
Cφw Þ þ Cφw þ Cφz Wx Wy ð1
Cφw Þ
Wz Sφw
 
þ ½Qz
ðMz þ Lz Þ Wx Wz ð1
CφÞw þ Wy Sφw þ Lx þ Mx
Int J Adv Manuf Technol (2008) 38:728–740 733

Y ¼ Py þ Ly þ My

n   h io
¼ Qx
Cφz Mx þ Sφz My þ Lx Cφz Wx Wy ð1
Cφw Þ þ Wz Sφw þ Sφz Wy2 ð1
Cφw Þ þ Cφw

 n   h io ð13Þ
þ Qy

Sφz Mx þ Cφz My þ Ly
Sφz Wx Wy ð1
Cφw Þ þ Wz Sφw þ Cφz Wy2 ð1
Cφw Þ þ Cφw
 
þ ½Qz
ðMz þ Lz Þ Wy Wz ð1
Cφw Þ
Wx Sφw þ Ly þ My

Z ¼ Pz þ Lz þ Mz

    
¼ Qx
Cφz Mx þ Sφz My þ Lx Cφz Wx Wz ð1
Cφw Þ
Wy Sφw þ Sφz Wy Wz ð1
Cφw Þ þ Wx Sφw

     ð14Þ
þ Qy

Sφz Mx þ Cφz My þ Ly
Sφz Wx Wz ð1
Cφw Þ
Wy Sφw þ Cφz Wy Wz ð1
Cφw Þ þ Wx Sφw
 
þ ½Qz
ðMz þ Lz Þ Wz2 ð1
Cφw Þ þ Cφw þ Lz þ Mz

3.2 Table/spindle-tilting type with a nutating head point RB and the cutter tip centre. The form-shaping
function matrix of this configuration can be obtained by
The table/spindle-tilting type configuration has one rotary the coordinate transformation matrices:
axis on the table and one nutating rotary axis on the spindle. 2 3
0 0
Figure 3 illustrates two pivot points RC and RB on the C and

 60 0 7
Trans Lx ; Ly ; Lz Rotðz;
φz ÞTrans Px ; Py ; Pz RotðW; φw Þ6 7
4 1
Lt 5
B axes, respectively. The pivot point RC is located arbitrarily
on the C-axis and the pivot point RB is chosen to be the 0 1
intersection of the nutating rotary B-axis and the axis of the ð15Þ
cutting tool. The offset vector Lx i +Ly j +Lz k is calculated
from the origin Ow to the pivot point RC and the effective Equating Eq. (4) and Eq. (15) leads to the following
tool length, Lt, represents the distance between the pivot equations:

2 3 2     3
Kx Cφz W  x Wz ð1
Cφw Þ þ Wy Sφw þ  Sφz W y Wz ð1
Cφw Þ
Wx Sφw 
6 Ky 7 6
Sφ Wx Wz ð1
Cφ Þ þ Wy Sφ þ Cφ Wy Wz ð1
Cφ Þ
Wx Sφ 7
6 7¼6 z w w z w w 7 ð16Þ
4 Kz 5 4 Wz2 ð1
Cφw Þ þ Cφw 5
0 0

2     3

Cφz Wx Wz ð1
Cφw Þ þ Wy Sφw þ Sφz Wy Wz ð1
Cφw Þ
Wx Sφw Lt
6 þCφz Px þ Sφz Py þ Lx 7
6 7
2 3 6 7
Qx 6      7
6

Sφ Wx Wz ð1
Cφ Þ þ Wy Sφ þ Cφ Wy Wz ð1
Cφ Þ
Wx Sφ L 7
6 Qy 7 6 z w w z w w t 7
6 7 ¼ 6
Sφ Px þ Cφ Py þ Ly 7 ð17Þ
4 Qz 5 6 z z 7
6 7
1 6  2  7
6
Wz ð1
Cφw Þ þ Cφw Lt þ Pz þ Lz 7
6 7
4 5
1
734 Int J Adv Manuf Technol (2008) 38:728–740

The joint parameters can be evaluated using the same

procedure similar to the table-tilting configuration. Notably,
B Zt the reference driving point of NC data in this configuration is
Yt Xt assumed to be the pivot point RB. This definition is adopted to
both the spindle-tilting and table/spindle-tilting type config-
RB Ot Lt urations, and is consistent with those used in most of the
commercial post-processor software packages. The complete
analytical equations for NC data can be expressed as:

Zw
Yw Xw

C Kz
Wz2
B ¼ φw ¼ arccos 0  φw  π ð18Þ
Ow
1
Wz2
RC
Offset vector
Lx i + Ly j + Lz k
Fig. 3 Coordinate systems of table/spindle-tilting type configuration

   
C ¼ φz ¼ arctan2
Ky Wx Wz ð1
Cφw Þ þ Wy Sφw þKx Wy Wz ð1
Cφw Þ
Wx Sφw ;
   

Ky Wx Sφw
Wy Wz ð1
Cφw Þ þKx Wy Sφw þ Wx Wz ð1
Cφw Þ ð19Þ

π  φz  π

points, and this problem is known as the linearization

X ¼ Lx þ Px ¼ Lt Wx Wz ð1
Cφw Þ þ Lt Wy Sφw


þ Sφz Ly
Qy
Cφz ðLx
Qx Þ
þ Lx
Y ¼ Ly þ Py ¼ Lt Wy Wz ð1
Cφw Þ
Lt Wx Sφw



Cφz Ly
Qy
Sφz ðLx
Qx Þ
þ Ly
Z ¼ Lz þ Pz ¼ Lt Wz2 ð1
Cφw Þ þ Lt Cφw þ Qz
3.3 Linearization problem
Theoretically, the CAD/CAM system generates the CL data
based on the assumption that the cutting tool moves linearly
between two successive points. However, the actual tool
motion trajectory with respect to the workpiece is not linear
and becomes curved since the linear and rotary axes move
simultaneously. The curved path deviates from the linearly
interpolated straight line path between successive path
problem. An algorithm must be developed to solve this
problem.
Assume that Pn, Pn+1 and Pn+2 are three continuous
adjacent points in CL data, plotted in Fig. 4. The vector of
ð20Þ
Pn in matrix form can be expressed as [Qn,x Qn,y Qn,z Kn,x
Kn,y Kn,z], where Qn,x, Qn,y and Qn,z are the components of
the position of the center of the tool tip, and Kn,x, Kn,y and
Kn,z are the components of the tool orientation. The
corresponding machine NC code of Pn is Mn =[Xn Yn Zn
Bn Cn]. As the five axes move simultaneously from the
ð21Þ current position Pn to the subsequent position Pn+1, each
axis is assumed to move linearly between the specified
points [18]. Therefore, each point in the actual curved path
ð22Þ can be expressed as follows:
Mm;t ¼ Mn þ t ðMnþ1
Mn Þ ð23Þ
where t is a dummy time coordinate ð0  t  1Þ. The
corresponding CL data Pm,t for Mm,t can be determined by
the forward kinematics equations, e.g. Eqs. (5) and (6) for
the table-tilting type and Eqs. (16) and (17) for the table/
spindle-tilting type. Moreover, each point in the ideal linear
tool path can be determined as follows:
Pn;t ¼ Pn þ t ðPnþ1
Pn Þ ð24Þ
Int J Adv Manuf Technol (2008) 38:728–740 735

Fig. 4 Linearization problem in Ideal linear tool path

multi-axis machining
Actual curved tool path

Interpolated tool path

M m ,t , Pm,t M m+1,t , Pm +1,t

d n ,t

Pn +1 , M n +1

Pn ,t , M n ,t Pn +1,t , M n +1,t

Pn , M n Pn + 2 , Mn+ 2

b
Fig. 5 Initiating dialog for the developed postprocessor. a table-tilting type. b table/spindle-tilting type
736
Fig. 6 Implementation dialog for generating NC data for table-tilting type configuration
The distance between Pm,t and Pn,t denoted as dn,t forms
a chordal deviation. If the maximum deviation (dn,t)max
exceeds the prescribed tolerance, then the additional
interpolated CL data Pn,t should be inserted into the original
CL data. Theoretically, the numerical iterative method for
calculating (dn,t)max must be adopted. Practically, the middle
point, t = 0.5, is often selected as the candidate point [10].
After the intermediate point Pn,t has been inserted, the
corresponding machine NC code can be generated.
4 Discussion
1. The main characteristic of the nutating rotary axis
configuration is the continuous motion between the
horizontal and vertical positions in a single setup on
the same machine. In the current configuration of the
commercial machine tool, the angle of inclination of
the nutating rotary axis is 45 degrees. This fact can be
explained by the equations derived above. The table-
tilting type is used as an example. Equation (5)
represents the tool orientation in relation to the
Int J Adv Manuf Technol (2008) 38:728–740
workpiece. The tool orientation relative to the work-
piece in the initial position, where the table surface is
horizontal, can be determined by substituting f z = f w =
0 into Eq. (5), and is given by [0 0 1 0]T. The nutating
rotary axis is assumed to rotate around X-axis by an
angle θ so that the components of the vector W are Wx
=0, Wy =–Sθ and Wz =Cθ. Substituting the above
conditions into Eq. (5), and setting f z =0 and [Kx Ky
Kz 0]T=[0 –1 0 0]T for the table surface in the vertical
position yields the following equation:
2 3 2 3
0 SθSφw
6
1 7 6
SθCθð1
Cφw Þ 7
6 7 6 7
4 0 5 ¼ 4 C2 θð1
Cφw ÞþCφw 5 ð25Þ
0 0
The solutions to Eq. (25) for θ and f w are θ=π/4 and
f w =π. Therefore, the table surface can be set in the vertical
position when the table is rotated through an angle π about
the nutating B rotary axis at an angle of inclination of π/4.
2. The nutating units on the five-axis machine tools can
enhance the flexibility of the machining strategy. How-
ever, the CL data considered are limited. Equation (7)
Int J Adv Manuf Technol (2008) 38:728–740
Fig. 7 Implementation dialog for generating NC data for table/spindle-tilting type configuration
Kz
Wz2 
shows that the condition  1
W 2   1 should be satisfied.
z
When the nutating axis is set at an angle of 45 degrees,
i.e. θ=π/4 and Wz =C45°, Kz is in the range 0 ≤ Kz ≤ 1.
Consequently, the CL data generated by the CAD/CAM
system can not be machined in this configuration if Kz is
a negative value.
3. The derived analytical equation of NC data is a general
form, which can be reduced to the orthogonal config-
uration. The table-tilting type is chosen as an example.
If the vector W is in the X-axis direction where Wx =1
and Wy =Wz =0, the configuration reduces to the CA
table-tilting type. The analytical equation of the NC data,
specifying for example Y-axis values, agrees with those
presented elsewhere [8] and can be expressed as follows:


Y ¼ ðQx
Lx ÞSφz Cφw þ Qy
Ly Cφz Cφw

ðQz
Lz ÞSφw þ Ly
737
Notably, in the cited work, the two rotary axes are
assumed continuously to intersect each other, and the offset
vector M ¼ 0i þ 0j þ 0k is used to derive the above
equation.
4. Based on the solutions for f z and f w, the cutting tool
may traverse the singular point where f w =0, Qx =Qy =0,
Qz =1 and f z is undefined [12, 18]. This singular
position occurs when f w =0 and the C-axis axis is
parallel to the cutting tool axis. As displayed in Fig. 4, if
the current position Pn+1 is the singular point, any value
of f z is theoretically acceptable since f z is undefined.
The next point Pn+2 should be read further to ensure that
f z varies linearly between two successive points. The
value of f z at position Pn+1 can be determined by
considering a linear change between Pn and Pn+2.
5. Feedrate control is an important issue in practical multi-
axis machining. Most controllers, such as FANUC and
Cincinnati Milacron, apply the feed rate number (FRN)
ð26Þ and G93 code to control the feedrate. FRN is
determined by the feedrate on the workpiece divided
738 Int J Adv Manuf Technol (2008) 38:728–740

Fig. 8 Snapshot of VERICUT®

simulation for table-tilting type
configuration

by the span length of the resulting path. When
rotational movements are combined with two or more
linear axes movements, determinations for the path
length become very complex. In most cases, an
adequate approximation of the true path length can be
determined by using only the linear displacement [19].
5 Implementation and verification
5.1 Software implementation
The aforementioned postprocessor methodology was imple-
mented in the Windows-XP environment using the Borland

Fig. 9 Snapshot of VERICUT®

simulation for table/spindle-tilt-
ing type configuration
Int J Adv Manuf Technol (2008) 38:728–740 739

C++ Builder programming language and the OpenGL
graphics library. A semi-sphere with a radius of 35 mm is
used to illustrate machining. The CL data are generated by
the commercial CAD/CAM system, PowerMILL [20]. Two
typical configurations of the machine tool, the table-tilting
and the table/spindle-tilting, were tested. Figure 5 (a) shows
the initiating dialogue of the developed postprocessor
software for the table-tilting type configuration. The user
can use the mouse button to rotate and zoom in on the
surface model of the machine tool, and the “Animate”
button to animate dynamically the machine tool. When the
user enters the relevant parameters, such as the offset vector
from the program origin toward the centre of the C-axis
rotary table, the system displays a figure to help the user to
input the parameters correctly, as shown in Fig. 6. Finally,
the target CL data are opened by clicking the “File” menu,
after which the NC data are generated accordingly. Figures 5
(b) and 7 show screenshots of the initiating and implemen-
tation dialogues, respectively, for the table/spindle-tilting
type. Notably, the set length from the gauge plane to the
tool tip centre and the distance from the gauge plane to the
pivot point should be considered in this configuration, since
the spindle head moves about the rotary axis.

50i
60j
70k. The distance from the gauge plane to the
pivot point of the B- axis is 100 mm and the set length from
the tool tip to the gauge plane in the tool library is 120 mm.
The results shown in Figs. 8 and 9 confirm the effectiveness
and feasibility of the proposed postprocessor algorithm.
5.3 Experimental verification
The generated five-axis NC data are further verified by
performing an experimental trial-cut. A table-tilting five-
axis machining centre (Deckel Maho DMU 70 eVolution)
equipped with a Heidenhain iTNC530 control is used to
machine the semi-spherical workpiece. The experiment is
conducted under the following conditions: (1) two ball-end
mills with diameters of 10 mm and 4 mm are used for
roughing and finishing, respectively; (2) the spindle speed
is 5000 rpm and the feedrate is 1000 mm/min; (3) the
workpiece material is made of 7075 aluminum alloy.
Notably, the positive direction of the C-axis of this machine

5.2 Solid cutting simulation

A solid cutting simulation software package, VERICUT® is

used to confirm the generated NC data. Given the raw
material size, the specifications of the cutting tool, NC data,
the type of controller, and the kinematics and physical
properties of an NC machine tool, it can interactively
simulate the material removal process of NC data. A table-
tilting type machine tool with a B-axis nutating rotary table
is built in the simulation environment and the finished part
is verified, as shown in Fig. 8. The relevant parameters
shown in Fig. 6 should be reflected in the dialogue of the
VERICUT® hierarchical component tree. For example, the
B-axis rotates about the X-axis by 45°, so the nutating table
is in an inclined plane and the vector of the B-axis is
W ¼ 0i
S450 j þ C450 k. The two rotary axes are as-
sumed not to intersect each other and the offset vector from
the C rotary axis to the B rotary axis is
5i
10j
15k.
Moreover, the raw material should be placed in the desired
position so that the offset vector from the program origin to
the C rotary axis is 30i þ 20j þ 10k. When the machine
setup has been completed, the system performs a realistic
3D simulation of the configured machine tool.
Figure 9 illustrates the “as-machined” workpiece cut on
a table/spindle-tilting type machine tool with a B-axis
nutating rotary head and a C-axis rotary table. As before,
the relevant parameters should be set according to Fig. 7.
The B-axis vector is W ¼ 0i þ S45 j þ C45 k. The offset Fig. 10 Practical machining experiment on the Deckel Maho DMU
vector from the program origin to the rotary C -axis is 70 eVolution. a roughing. b finishing
740
tool is along the negative Z direction. The actual NC value
of the C-axis is the negative value given by Eq. (11).
Figure 10 shows the actual machining process, and reveals
that the developed postprocessor can correctly and success-
fully generate five-axis NC data.
6 Conclusion
A postprocessor methodology for the five-axis machine
tool with a nutating table and head configuration has been
developed. The general analytical equations of NC data
were determined by the homogeneous coordinate transfor-
mation matrix, and the forward and inverse kinematics. The
derived NC data equation is useful for such machine tools,
whose rotary axes need not intersect each other and for
which the angle of inclination of the non-orthogonal axis is
variable. Introducing the variable angle of inclination can
increase the usefulness of the derived equations since the
NC data can be reduced to the orthogonal configuration.
The presented algorithm can also be applied to the
configuration of the multitasking mill/turn machine tool
[21] whose linear and rotary axes are both non-orthogonal.
This work is currently under way.
Acknowledgements The financial support of the National Science
Council of the Republic of China under grant NSC 95-2221-E-150-101 is
gratefully acknowledged. The authors also would like to thank the Metal
Industries Research & Development Centre for use of five-axis equipment
and Mr. Bacchus Yu in Delcam Taiwan for his useful comments.
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