This paper describes the development of a five-axis tool path generation algorithm for the machining of
complex shaped parts using flat-end tools. In order to reduce the machining time and to ensure optimal
quality, the step-over is optimized in each tool contact point. This step-over calculation is obtained
through the integration of a newly developed algorithm for material removal simulation. The latter is
performed by calculating swept volumes which represent tool motions interpolated according to the
machine kinematics. The developed algorithm has been implemented for contour like (spiral) strategies
and validated through the machining of an industrial example.