This paper presents a method of determining the shape of the surface swept
by a tool that follows a 5-axis tool path for machining curved surfaces. Th
e method consists of discretising the tool into pseudo-inserts and identify
ing imprint points using a modified principle of silhouettes. An imprint po
int exists for each pseudo-insert and the piecewise linear curve connecting
them forms an imprint curve for one tool position. A collection of imprint
curves is joined to approximate the swept surface. This method is simple t
o implement and executes rapidly. The method has been verified by comparing
predicted results of a 3-axis tool path with analytical results and predic
ted results of a 5-axis tool path with measurements of a part made with the
same tool path. (C) 2000 Elsevier Science Ltd. All rights reserved.