Kinematics and geometric features of the s-cone test piece: identifying the performance of five-axis machine tools using a new test piece

The design of machine parts of different sizes and shapes has become relevant in the manufacturing industry which requires five-axis machine tools of high dynamic performance; different machining test pieces have been used to test and reflect the machine tool’s performance. The S-shaped is still under development and consideration of which a new test piece better than the S-shaped part has been recommended to be put forward making the NAS979 the only standardized test piece; however, it has some limitations. Hence, this study proposes a new test piece to objectively satisfy the demand for machine tools with higher dynamic performance, which shows much improvement over the standard NAS979 and is the best alternative to the S-shaped test piece, and it combines the geometric and kinematic features of both test pieces. Geometrically, it has non-uniform surface continuity, variable twist angle, and variable curvature; and the cutting tool moves in close and opened angles along the tool path; there is sudden rise and fall of axes’ velocity, acceleration, and jerk with much impact during machining which makes the S-cone test piece be machined by only five-axis machine tools with high dynamic performance, and has a better dynamic performance identification effect than the S-shaped test piece based on the trajectory test. Detailed work on the validation of the machine tool’s dynamic performance using the S-cone part will be captured next part of this study.