This paper proposed a method to determine the path scallop of toroidal cutter in five-axis milling during a complex surface machining. A mathematical algorithm was developed by taking into consideration the impact of the helical angle and inclination angle. The applicability of the proposed method was tested using two model parts with diverse surface profiles. The result showed that the method was effectively used to generate the path scallop data. Moreover, the program simulation could also generate the shape of a machined surface. The effect of the helical angle to the scallop height was also tested and the result showed that the helical angle tended to decrease the scallop height. On the other hand, a larger inclination angle produced a larger scallop height. The verification test using Siemens-NX proved that the method was accurate.
