Inverse kinematics for a novel hybrid parallel–serial five-axis machine tool

•A unique successful postprocessor for a hybrid parallel-serial machine tool is developed.•Smart machining must be accomplished without forcing the tool to make sharp turns when HSM controls detect a turn approaching.•NC codes are recalculated to form a new path for the pivot that can avoid the discretization near the singularity points in this study.•The novelty of the paper is successfully to propose a new hybrid parallel-serial five-axis machining model.•The manufacturers that are interested in integrating the inverse kinematics into the design process of their hybrid product. Instead of obsessively emphasizing to interpolate more points from the linearization algorithm, the NC codes are recalculated to form a new path for the pivot that can avoid the discretization near the singularity points in this study. In previous studies, orientable-spindle machines were directly used to generate smooth tool paths traversing singular positions through inverse kinematics. In many characteristics and practices, PKMs (parallel kinematic machines) and serial machines are the opposites of each other. Fully PKMs have relatively very limited working-space, especially in terms of orientation characteristics. Fully serial machines have a problem of error accumulation. This paper presents a modular method to construct a postprocessor system for a novel hybrid parallel-serial five-axis machine tool. A hybrid parallel-serial mathematical model is introduced to analyze a structural configuration. The configuration decomposition of machine tools is used to create the kernel of the postprocessor. The proposed modified Denavit–Hartenberg notation is used in the coordinate conversion procedure, and then an algorithm is used for developing the inverse kinematics of five-axis machines. The feasibility of solutions depends on the surface normal along the tool path satisfying certain orientation constraints. The proposed algorithm can be easily adapted to convert between cutter contact path and cutter location code and implemented on computer-aided design and computer-aided manufacturing systems. Examples with end-milling and side-milling tools are demonstrated and real cutting parts are implemented for verifying the algorithm.