Abstract: While determining the optimal tool orientation for five-axis flat-end cutter machining, most algorithms only pursue the maximum material removal rate without taking into account other factors, such as the machining quality and the smoothness between adjacent tool orientations. The metrics of tool orientation considering all above are established. Aiming at the minimal weighted metrics, an optimization model with several springs is established, and the problem of finding optimal tool orientation is treated as the mechanical equilibrium problem. The fixed point at Gaussian map will converge to locus of the optimal tool orientation. The simulation results show that the weight of SE and DF influences the machining efficiency and quality, respectively, and the movement smoothness is affected by DW and DM weights. The optimal tool orientations with high efficiency, stable machining and smooth movement can be determined using an appropriate group of weights.

Key words: Five-axis NC machining, Metrics, Optimal tool orientation, Smoothness