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Sculptured surfaces have been widely used in various engineering applications. With the development of five-axis machining technology, five-axis machine tool has played a more and more important role in manufacturing sculptured surfaces. This article proposed a complete five-axis machining process planning for vehicle rear bumper mold. First, a numerical model considering tool inclination was developed to predict topography and surface roughness in ball-end milling processes. And then experimental verification was conducted. Second, according to the simulation results, it can be concluded that surface roughness decreases significantly with the tilt angle increasing from 0° to 5°. When the tilt angle is 10°, surface roughness gets the smallest value. What is more, surface roughness increases slightly from 10° to 30°. In the case of the permitted surface roughness, larger feed rate per tooth and the radial cutting depth can be chosen. Finally, a process strategy was made through the analysis of the mold in which the parameters were chosen according to the simulation results above

Tool path planning and milling surface simulation for vehicle rear bumper mold