An Optimization Method for Five-axis Plunge Milling Tool Path Considering SIRD

• Identifies unreasonable tool path planning as the root cause of SIRD in five-axis plunge milling. • Develops an SIRD discrimination model using cutter position and axis vector as variables. • Optimized tool path reduces residual material volume to less than 60% of gradually decreasing plunge depth. • Enhances machining efficiency and enables automated tool path optimization without operator experience.