Development of post processors and procedures for computer numerical controlled fabrication of a near shape mold

The transformation equations for a 5-axis computer numerically controlled gantry mill/polisher were derived. An analytical and experimental study was conducted to identify two unknown dimensions in the mill geometry. A study was made to define the error induced by a non-orthogonality of the mill's linear and rotation axes. A process was developed to create the machine motion commands for producing mold frames. An aircraft fuselage mold surface was produced using 3-axis motion transformation with a non-orthogonal rotational axis position.