AT73.

01 CAD/CAM

CAM
COMPUTER AIDED
MANUFACTURING
BY ERIK L.J. BOHEZ
AUGUST 2005

BASICS OF CNC MACHINE TOOLS

TYPES OF CNC MACHINES:
-LATHES 50%
-MILLING MACHINES 30%
-OTHERS 20 %
-EDM MACHINES WIRECUT DIESINKING
-SHEET METAL MACHINES
-TEXTILE MACHINES STICHING WEAVING
-BENDING MACHINES
-AUTOMATED STORAGE AND RETRIEVAL SYSTEMS

TAXONOMIE OF A CNC MACHINE:

-CNC CONTROL
-SERVO SYSTEM
-MEASURING SYSTEM
-MECHANICAL STRUCTURE
-PLC (PROGRAMMABLE LOGIC CONTROL)
-ATC (AUTOMATIC TOOL CHANGER)
-ATW (AUTOMATIC WORKPIECE CHANGER)
-AXIS CONFIGURARION X Y Z A B C U V W

CNC CONTROLS
-2D 3D 4D 5D
-INTERFACE RS232 RS422 RS485 ETHERNET DNC
-BTR FEATURE (BEHIND TAPE READER) DRIP MODE
-USERFRIENDLYNES GOOD MORNING OPERATOR
-PC INTERFACE MS WINDOWS
-SELF DIAGNOSIS ONLINE HELP TROUBLE SHOOTING
-COLLISION DETECTION
-OPEN SYSTEMS

CNC PROGRAMMING LANGUAGES

G-CODES
G01 X100.000 Y200.000 Z300.000 A360.000 B500.000 F1000
G00 X200.000 Y400.000 Z400.000 A450.000 B300.000
G90 G91 G54
M05, M01, M03

HIGH LEVEL LANGUAGE

APT (AUTOMATICALLY PROGRAMMED TOOLS)
L1 = LINE/P1,P2
C1 = CIRCLE/P1,R
.
.
GOTO/P1
GO
GRAPHIC MACHINING
INTERACTIVE COMPUTER GRAPHICS MASTERCAM UG
VERIFICATION SOFTWARE
VERICUT GRAPHIC SIMULATION OF METAL REMOVAL
6

1953 vacuum tube based Numerically Controlled milling machine

7

NC Lathe in 1956
8

1961 NC machine based on transistors

NC Control with Integrated Circuits 1968

10

1978 CNC Control with Micro-Processor

11

12

13

14

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POSITIONING LOGIC OF A CNC MACHINE:

THE SEQUENCE IN WHICH THE AXES MOVE WHEN G00
IS ACTIVE (UNDER G00 ALL AXES DO NOT MOVE
SIMULTANOUS)
THIS IS DIFFERENT FOR DIFFERENT TYPE OF MACHINE
THE MAIN FACTOR TO SEQUENCE IS SAFETY
FOR THE 5-AXIS MAHO IN AIT CIM LAB IT IS:
. ??????

16

Following example shows the typical CNC Part program which contains
the NC words.
%
O503
N0001 G90 G71 G54 G94
N0002 T07 M06 S1000 M03
N0003 G00 X10.500 Y73.500 Z0.000 M08
N0004 G01 X28.000 Y73.500 F200
N0005 G02 X119.000 Y73.500 I45.5 J0.000
|
N0112 M05 M09
N0113 T0000
N0114 M30
%
17

Each program is identified by the program number which is right in the beginning (O503).
Each line in the part program is known as Block, which is identified by the
`N' word (N0001 etc). Each block contains certain other words. A typical CNC program
has following words.
1) Sequence number (N word) :
Used to identify the block. e.g. N0010.
2) Preparatory word ( G word) :
Used to prepare the controller for instructions that are to follow
e.g. G02 prepare the NC controller unit for circular interpolation along an arc
in the clockwise direction.
3)Coordinates (X,Y,Z etc) :
These are the geometric coordinate positions of the tool.
4) Feed rate ( F word) :
Used to specify the machining feedrate of the machine.
5) Cutting speed/RPM ( S word) :
Specifies the rate at which the spindle rotates.
6) Tool,selection ( T word) :
Specifies which tool is to be used in the machining operation.
7) Miscellaneous functions (M word) :
Specifies certain auxiliary or miscellaneous functions which are available on the machine.
e.g. M03- Spindle rotate clockwise, M08- Coolant on, M06- Tool change etc
Most of these Part programing langauge codes are standardised by EIA/RS244
(Electronic Industries Association), ISO/R840 (International Standard Association) and
18
DIN 66 025 international standards.

RIGHT HAND RULE

19

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21

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RIGHT HAND RULE FOR ROTATIONAL AXES

23

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EDM DIE SINKING

EDM WIRECUT
RULED SURFACES
COMPLEX SHAPES
DEPENDS ON ELECTRODE

28

29

PART MADE WITH A 4-AXIS DIE SINKING EDM MACHINE

XYZC AXIS
30

4-AXIS WIRECUT EDM AXIS CONTROL

31

5-axis cnc machine

32

KINEMATIC CHAIN DIAGRAM OF 5-AXIS MACHINE

33

34

XYZCB and UV some call this a 7-axis machine

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36

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39

40

CNC SINGLE AXIS SERVO LOOP

Tf*
Vf*

X1*

Pos

Vel

.
.
.

Xn*

X1

V1

T1

41

SLIDE OVERTRAVEL PROTECTION

42

REVOLVING BALL SCREW

TRANSFORM SLIDING FRICTION TO ROLLING
NO BACKLASH

43

UPHILL MILLING

44

Conventional milling versus climb milling

The direction of feed influenced machining performance.
Conventional milling - up milling
Feed movement opposite to tool rotation.
Width of chip starts from zero and increases.
Tooth meets the workpiece at the bottom of cut.
Upward force tends to lift up workpiece.
More power required - rubbing provoked by chip beginning
at minimum width.
Surface finish marred (spoiled) due to the chips being carried
upward by tooth.
Chips fall in front of cutter - chip disposal difficult.
Faster wear on tool than climb milling.
Conventional milling preferred when milling castings or
forgings with very rough surfaces.
45

46

DOWNHILL MILLING

47

Climb milling - down milling

Feed movement and tool rotation same direction.
Width of chip starts at maximum and decreases.
Tooth meets workpiece at top of cut.
Easier chip disposal - chips removed behind cutter.
Less wear - increases tool life up to 50%.
Improved surface finish - chips less like to be carried by the tooth.
Less power required - cutter with high rake angle can be used.
Climb milling exerts a downward force on workpiece
fixtures simple and less costly.
Climb milling preferred when milling heat treated alloys,
stainless steel - reduces work hardening. Climb milling way cause
chipping in milling hot rolled materials due to hardened layer on
the surface.

48

Milling Machines Backlash

Backlash is a term that applies to machine tools. Backlash refers to the
"play" or excessive amount of clearance between the machine hand
wheel screw and the nut attached to the machine table or slide (Figure1).

Figure 1. Backlash
49

Backlash is common on manual machine tools, especially milling

machines, and is due to wear or adjustment. Backlash must be
compensated for. To compensate for backlash, you must get, and keep
the slide (table) and screw in contact with one another (Figure 2).

Figure 2. Screw rotation direction maintains contact between

the screw and the table nut.
50

To accomplish this, when positioning the table, you must always

move the table in the same direction. When positioning the table for
locating a drilled hole for example, the direction you moved the
table to pick up the edge of the part is the same direction the handle
needs to be turned for positioning. If you go past the required
setting, it is necessary to go back way from the setting at least onefourth of a turn to eliminate the backlash and then come back to the
required dial setting.
It is also very important to keep in mind the cut
direction as it relates to backlash. On conventional
milling machines, that are not equipped with
backlash eliminators, the feed direction should
always be against the spindle rotation (Figure 3).
Figure 3. Conventional Milling
51

This is known as conventional or up

milling. By working the cutter rotation
against the feed, the backlash is taken up.
Climb milling, or down milling, must be
avoided on a machine not equipped with
a backlash compensation mechanism.
In climb milling, the feed direction is
into the cutter rotation (Figure 4).

52

Therefore, climb milling, as the name implies, causes the tool

to want to climb onto the part. When this happens, the workpiece
gets pulled into the cutter causing the excessive cutting pressure
to seriously damage the workpiece, cutter, and milling machine arbor.
CNC machines are equipped with ball screws and are designed to
machine with the climb milling process. Wherever possible Climb
(down) milling should be done especially with larger cutters.
Before operating any milling machine, find out if the machine
is equipped with a backlash eliminator.

53

MEASURING SYSTEM
DIRECT - INDIRECT
ABSOLUTE - INCREMENTAL

DIRECT

INDIRECT
ABSOLUTE ANALOG

ABSOLUTE
DIGITAL
DIRECT
INCREMENTAL
54

MACHINE TOOL COMPONENTS

Mechanical structure
Drives
Measuring system
Overtravel Protection
PLC
Servo Control
Analog/Digital
Sercos
Networking
55

MECHANICAL STRUCTURE
5-AXIS MACHINE
HORIZONTAL/VERTICAL MILLING MACHINE
5-AXIS LATHE
VIRTUAL AXIS MACHINE
KINEMATIC CHAIN DIAGRAM
REVOLVING BALL SCREW - BACKLASH

56

DRIVES
STEPPER MOTORS
DC MOTORS
ASYNCHRONOUS AC MOTORS
SYNCHRONOUS AC MOTORS
LINEAR MOTORS

57

PLC - PROGRAMMABLE LOGIC CONTROL

Cyclic Operation
Cycle Time

Ladder diagram
KNOW I/O OF YOUR PLC
Trouble Shooting
Integration

58

SERVO CONTROL
ANALOG - DIGITAL
SERCOS STANDARD
BLOCK CYCLE TIME
SERVO UPDATE RATE
COMMUNICATION
FIELDBUS

59

Drive/Controller System Based on Analog Velocity Drive

Drive/Controller System Based on Analog Current Drive

Drive/Controller System Based on Power Block Drive

60

SERCOS Ring Configuration

Profile Accuracy of an Analog

System with 1000 Hz Update

61

Profile Accuracy of an
Analog System with
1000 Hz Update

Transmission : data Cyclic Data strings transmitted quickly within a fixed cycle
and in synchronization with each other.
Cyclic Transmission data includes:
commanded and actual servo information.
status messages.
Cyclic means that, during a given cycle, the master can communicate with all
drives.
Non-Cyclic Data Transmission : data strings which need to be transmitted but do
not require real-time processing.
Non-Cyclic Transmission data includes:
servo tuning parameters.
limit switch +EOT, - EOT values.
Non-Cyclic means that the master can communicate during a cycle with only one
drive at a time

62

 Data transfer takes place in telegrams.

SERCOS interface recognizes three types of telegrams:
Master Synchronization Telegram (MST) : is broadcast by the
master at the beginning of a transfer interval. MSTs are short
and are used to synchronize.
Master Data Telegram (MDT) : is transmitted by the master once
during a cycle. MDTs are lengthy and transfer data from the
master to the drives.
Drive Telegram (AT) : is transmitted by the slaves and serve to
transfer data from the drives to the master.

63

CNC DRIVE COMPARISON TABLE

Measur e
W ires between axes and controller
(includes feedback, limit switches)
Extra wiring in system due to feedback
connecting to both drive and controller
Grounds of drive and controller
interconnected
Time to commission on new machine.
Noise and resolution concerns

Smoothness of profile
Speed of response

Availability
Cost

SERCOS system
2 fiber-optic cables
per system
None
No
Fast
Low: Very few
pla ces for noise to
degrade perf. All
command signals
are 32 bit
Excelle nt
High, especially for
high-axis count
systems
Growing
Drive slightly more
expensive; reduced
wiring and
installation time,
extension of I/O,
drive features
usually reduce
overall cost.

Analog
13-16
wires per
6- 8
wires per
Yes

Analog
13-16
wires per
6- 8
wires per
Yes

Usually

MediumHigh:
command
resolution
and
commonExcellent
High

Medium
Moderate:
common
mode
noise on
command
Excellent
High, but
powerful
controller
Wide
Nominally
priced
drive, but
powerful
controller
may be
required
for high

Medium Moderate:
degradati
on of
analog
current
Excellent
High, but
very
powerful
Growing
Drive le ss
expensive
;
increased
wiring
and high
power
controller

Wide
Nominally
priced
drive and
controller.
Wiring
issues
can raise
installed

Power
16-20
wires per
None

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ROBOT FOR LOADING UNLOADING CNC

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INSTEAD OF INDIVIDUAL I/O CONNECTIONS

BETWEEN PLCSEACH PLC CONNECTS TO A
COMPUTER NETWORK - FIELDBUS

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FIELDBUS ADVANTAGES - CONT

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FIELDBUS ADVANTAGES - CONT

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REAL TIME CONDITION FOR CNC SERVO CONTROLLER

BLOCK CYCLE TIME } SERVO UPDATE RATE

REAL TIME OPERATING SYSTEM HAS A
DETERMINISTIC RESPONSE TIME
COMPUTER NETWORKING
-ETHERNET STOCHASTIC RESPONSE TIME NO REAL TIME
-TOKEN PASSING (RING OR BUS) REAL TIME
INTELLIGENT SENSOR = SENSOR THAT CAN CONNECT TO
COMPUTER NETWORK

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Reading assignment pdf file is available

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INVERSE KINEMATICS
OF 5-AXIS MACHINE TOOL

77

Kinematic Modeling of Machine Tool

Structural Modeling of Machine Tool
Thermal Modeling of Machine Tool
Dynamic Modeling of Machine Tool

78

WHY 5 DEGREES OF FREEDOM

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5 degrees of freedom is the minimum to

position two rigid bodies in any relative
position and orientation

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81

(Direct/Forward) Kinematics is the process of calculating the position

in space of the end of a linked structure, given the positions of all the
joints. It is easy, and there is only one solution.
Inverse Kinematics does the reverse. Given the end point of the
structure, what positions do the joints need to be in to the achieve
that end point. It can be difficult, and there are usually many or
infinitely many solutions.

82

A=000.000
B=000.000
X=000.000
Y=000.000
Z=000.000

Machine tool reference position

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KINEMATIC CHAIN DIAGRAM OF 5-AXIS MACHINE

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O1 Fixed
To part
To A-Body
CL-Vector
x1, y1, z1,
i1, j1, k1

Workpiece coordinate system O1

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O4 Fixed
To Frame

O4 Machine Coordinate System

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O2 Fixed
To B-Body
Workpiece
Offset:
xO1O2 = 37.5mm
yO1O2 = 64.952mm
zO1O2 = 0.0 mm

O2 Coordinate System z2 coincides with A-axis

87

O2 Fixed
To B-Body
Specific Machine
Parameters:
zO3O4 = - 415.000 mm

Tool Length Compensation:

zTO4 = -100.000 mm
O2 Coordinate System Facilitates Coordinate Transform
From O2 to O3 O2 and O2 axes have same orientation
88

Specific Machine
Parameters:
xO2O2 = 0.000 mm
yO2O2 = 0.000 mm
zO2O2 = -290.000 mm
zO2O3 = 15.000 mm
Coordinate Transform O2 to O3:
x3 = - z2
y3 = y2
z3 = x2 + z O2O3
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90

Workpiece
Moves

Rotation A Orientate CL-Vector in Horizontal Plane

91

Workpiece
Moves

Rotation B Orientate CL-Vector Parallel to Tool Axis

92

Top View Illustrate Effect of A and B Rotation:

CL-Vector Parallel to Tool Axis
93

Side View Showing the Required Y and Z translation

after Rotations A and B
94

Side View Showing the Required X translation

after Rotations A and B
95

Workpiece
Moves

CL-Vector Position after A and B rotation and X translation

96

Top View of CL-Vector Position after A and B rotation

and X translation
97

Side View of CL-Vector Position after A and B rotation

and X translation ( Required Y and Z Translation is clearly
Visible)
98

Workpiece
Moves

Machine Tool Position after Rotations A and B and

Translation X and Y
99

Side View of CL-Vector Position after A and B rotation and X

and Y translation ( Required Z Translation is clearlyVisible)
100

Close Up View of Tool and Workpiece position after A, B Rotations

and X,Y Translations
101

A= - 45.000
B= - 35.269
X= 301.560 mm
Y= 44.160 mm
Z= - 330.200 mm

Machine Tool Position after Rotations A,B and Translations X,Y

Of Workpiece and Translation Z of Tool
102

Top View after A,B,X,Y and Z movements

Tool tip and CL vector Coincide
103

(* Geometry Transform for Maho600E machine - Ref Fig1 *)

(* Example CL-Point *)
i1 = Sqrt[3]/3;
j1 = Sqrt[3]/3;
k1 = Sqrt[3]/3;
x1 = 100;
y1 = 100;
z1 = 100;

104

(* Workpiece Offsets *)
xo1o2 = 10;
yo1o2 = 10;
zo1o2 = 10;
(* Machine parameters*)
zo2o2p = -250.314;
zo2po3 = 0.08;
zo3o4 = -350;
zto4 = -100;

105

(* Computation of A and B angle *)

A = ArcTan[j1/i1];
B = - ArcSin[k1/Sqrt[i1^2 + j1^2 + k1^2]];

106

(* Coordinate Transform from o1 to o2 *)

x2 = x1 + xo1o2;
y2 = y1 + yo1o2;
z2 = z1 + zo1o2;
(* Rotation A in o2 - Positive rotation oposite ISO *)
x2a = x2 Cos[A] + y2 Sin[A];
y2a = -x2 Sin[A] + y2 Cos[A];
z2a = z2;

107

(* Coordinate Transform from o2 to o2p *)

(* zo2o2p is a machine dependent parameter *)
x2pa = x2a;
y2pa = y2a;
z2pa = z2a + zo2o2p;
(* Coordinate Transform from o2p to o3 *)
(* zo2po3 is a machine dependent parameter *)
x3 = -z2pa;
y3 = y2pa;
z3 = x2pa + zo2po3;
108

(* Rotation B in o3 *)
x3b = x3 Cos[B] - z3 Sin[B];
y3b = y3;
z3b = x3 Sin[B] + z3 Cos[B];
(* Coordinate transform to O4 *)
x4w = -x3b; y4w = -y3b; z4w = z3b + zo3o4;
(* Translation X,Y workpiece moves - and Z tool moves *)
(* zo3o4 is a machine parameter *)
(* zto4 is the tool length offset *)
x4wX = x4w + X; y4wY = y4w + Y; z4wXY = z4w
x4TZ = 0; y4TZ = 0; z4TZ = ZTo4 + Z;
(* After A, B, X, Y, Z we require *)
x4wX = x4TZ = 0; y4wY = y4TZ = 0; z4TZ = z4wXY
X = x4w; Y = y4w; Z = z3b + zo3o4 - zTo4

109

5-AXIS POSTPROCESSOR
-INVERSE KINEMATICS
-LINEARIZATION
-FEED RATE COMPENSATION

110

CAM TOOLPATH = PIECEWISE LINEAR APPROXIMATION

111

REAL TOOLPATH ON 5-AXIS MACHINE IS A CURVE

112

PROBLEMS WITH 5-AXIS TOOLPAT ON REAL MACHINE

-CURVED REAL TOOLPATH OUT OF TOLERANCE
-MACHINE SLIDE TRAVEL NOT EQUAL TO TOOLTIP TRAVEL
SOLUTIONS
-LINEARIZATION
-FEEDRATE ADJUSTMENT

113

LINEARIZATION

BECAUSE THE REAL TOOLPATH ON THE 5-AXIS MACHINE

IS A CURVE THE POSTPROCESSOR WILL INSERT EXTRA
CL POINTS SO AS TO APPROXIMATE THE STRAIGHT LINE
WITHIN TOLERANCE
114

Technological Advantages of 5-Axis machining

1.Better surface roughness

115

Periodical build-up and breaking-off of the build-up cutting edge at

Speed of about 50 m/min
116

5-axis milling techniques Flat end mill with lead/lag

tilt angle

Point Milling Cutter Contact Point (CC point)

In case of 5-axis the CC point has always optimal cutting speed

117

5-axis milling techniques Ruled surface swarf milling

Peripheral Milling Swarf milling cutter contact curve

Very smooth surface
High metal removal rate
Large overcut/undercuts
118

5-axis milling techniques Head milling with flat endmill

super finish of convex surfaces

-Milling with the bottom of the endmill The bottom plane is tangent
to the workpiece surface.
-This method is only used for finishing convex surfaces
- Non-optimal cutting conditions at CC point High friction
- Allows to obtain excellent surface finish used to obtain optically
Perfect surfaces
119

Ra in m
Machined surface
roughness

H I

120

Shape error versus cutter orientation

121

Scallop or cusp height

Scallop height in case of ballnose

122

Scallop height in case of flat end mill under angle

123

Selection of diameter and slope of tool for concave surface

124

Machining a flexible workpiece with a ballnose or flat end mill

125

Dimensional deviation due to bending of the tool

126

3D

5D

Machining of a rib
127

STUDY OF 5-AXIS MACHINE

CLASSIFICATION OF FIVE AXES MACHINES
A) ROTATION AXES ARE ON TOOL SPINDLE,
B) ROTATION AXES ARE ON MACHINE TABLE
C) COMBINATION OF BOTH

128

FIVE AXIS M ACHINES WITH THE ROTAT'ON AXES IM PLEM ENTED ON THE TOOL AXIS SPINDLE
ADVANTAGES:
0 THESE M ACHINES CAN MACHINE VERY LARGE WORKPIECES.
0 THE M ACHINE AXIS VALUES OF THE NC PROGRAM XYZ DEPENDENT ON THE TOOL LENGTH ONLY. A NEW
CLAMPING POSITION OF THE WORKPIECE IS CORRECTED WITH A SIM PLE TRANSLATION. THlS HAPPENS WITH A
ZERO TRANSLATION IN THE CNC CONTI:OL OF THE M ACHINE.
DISADVANTAGES:
0 THE DRIVE OF THE M AIN SPINDLE IS VERY COM PLEX. ONLY IN CASE THAT THE WHOLE SPINDLE WITII THE
MOTOR ITSELF IS ROTATING CAN WE OBTAIN A SIMPLE CONSTRUCTION.
0 THERE IS A LOWER STIFFNESS BECAUSE THE ROTATION AXIS OF THE SPINDLE IS LIM ITING TI-IE FORCE
TRANSM ISSION. AT HIGH REVOLUTIONS PER M INUTE (HIGHER THAN 5000 RPM ) THERE IS ALSO A COUNTER ACTING
MOM ENT BECAUSE OF THE GYROSCOPIC EFFECT WHICH COULD BE A DISADVANTAGE IN CASE THE TOOL SPINDLE
IS TURNED VERY FAST.
0 CIRCULAR INTERPOLATION IN A RANDOM PLANE AND DRILLING CYCLES UNDER RANDOM ORIENTATION ARE OFTEN
NOT IMPLEM ENTED.
0 A CHANGE IN THE TOOL LENGTH CANNOT BE ADJUSTED BY A ZERO TRANSLATION IN THE CONTROL UNIT, OFTEN
A COM PLETE RECALCULATION OF THEPROGRAM IS REQUIRED.
IMPORTANT APPLICATIONS OF THIS TYPE:
ALL TYPES OF VERY LARGE WORKPIECES SUCH AS AIRPLANE WINGS

129

130

131

MACHINES WITH TWO AXES ON THE CLAMPING TABLE;

ADVANTAGES:
IN CASE THAT THE SPINDLE IS HORIZOINTAL WE ARE OBTAINING IN ALL CASES OI'TIM AL CHIP REM OVAL THROUGH
THE GRAVITATIONAL EFFECT OF THE CHIPS JUST DROPPING AWAY.
THE TOOL AXIS DURING MACHINING IS ALWAYS PARALLEL TO THE Z AXIS OF THE MACHINE. SO THE DRILLING
CYCLES CAN BE EXECUTED ALONG Z-AXIS OF M ACHINE. CIRCLES UNDER A CERTAIN ORIENTATION OF THE
WORKPIECE ARE ALWAYS EXECUTED IN THE XY PLANE OF THE MACHINE. THE AHOVE M ENTIONED FUNCTIONS CAN
BE EXECUTED IN THE SIM PLE 3-AXES NUM ERICAL MODE.
THE COMPENSATION OF THE TOOL LENGTH HAPPENS ALL THE TIM E IN THE NC CONTROL OF THE MACHINE, AS
WITH 3-AXES M ACHINES.

DISADVANTAGES:
* MACHINES WITH A ROTATING TABLE ARE ONLY FOR WORKPIECES WITH LIM ITED DIM ENSIONS.
* THE USEFUL WORKSPACE IS USUALLY M UCH SM ALLER THAN WITH LINEAR 3 AXES M ACHINES.
THE TRANSFORMATION OF THE CARTESIAN CAD/CAM COORDINATE (XYZIJK) OF THE TOOL POSITION TO
THE M ACHINE AXES POSITIONS (XYZAB OR C) IS DEPENDENT ON THE POSITION OF THE WORKPIECE ON
THE M ACHINE TABLE. THIS M EANS THAT IN CASE THE POSITION OF THE WORKPIECE ON THE TABLE IS
CHANGED THIS CANNOT BE M ODIFIED BY A TRANSLATION OF THE AXES SYSTEM TO THE XY SYSTEM OF THE
XYZ VALUES IN THE NC PROGRAM . THEY M UST HE RECALCULATED. IN CASE THE CONTROL OF THE NC
MACHINE CANNOT TRANSFORM CARTESIAN COORDINATES TO MACHINE COORDINATES, THEN A NEW CNC
PROGRAM. MUST GENERATED WITH THE POSTPROCESSOR OF THE CAD/CAM SYSTEM EVERYTIM E THE
POSITION OF THE WORKPIECE CHANGES.
IMPORTANT APPLICATIONS FOR THIS TYPE:
0 5-SIDED CUTTING OF ELECTRODES FOR EDM , ELECTRODES AND OTHER WORKPIECE.
0 MACHINING OF PRECISION WORKPIECES.
0 TURBINES AND TIRE PROFILES WITH A CERTAIN WORKPIECE GEOM ETRY ROTATFD OVER A CERTAIN ANGLE.
THE SAM E NC PROGRAM CAN HE REPEATED AFTER THE ZERO OF THE ROTATION AXIS HAS BEEN INCLINED OVER
A CERTAIN ANGLE.
132

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134

135

MACHINES WITH A TURNING TABLE AI' D A ROTATING TOOL SPINDLE

NOWADAYS THERE ARE M ANY MACHINES ON THE MARKET WITH ONE ROTATION AXIS ON THE TOOL SPINDLE AND
ONE ROTATION AXIS ON THE TABLE. THEY ARE HOWEVER COM BINING M OST OF THE DISADVANTAGE OF BOTH
PREVIOUS TYPES OF M ACHINES AND ARE OFTEN USED FOR THE PRODUCTION OF SM ALLER WORKPIECES. THE
CLAMPING SURFACE IS LIM ITED TO 400X400 MM WHICH IS HOWEVER FOR M ANY COMPLEX PARTS SUFFICIENT.
A LARGER WORKING RANGE IS PRACTICALLY REALIZABLE BY EQUIPING THE M ACHINE WITH LONG SHAPE AND
T-TABLE ALONG THE X-AXIS ROTATION THE CONSTRUCTION OF THIS MACHINE IS SIM PLER THAN THE PREVIOUS
TYPE SO THAT ROTATING AND PENDELING AXIS CAN BE BUILT IN THE TOOL SPINDLE. OFTEN THERE IS A LARGE
ANGULAR MOVEM ENT POSSIBLE OF THE TOOL. THE APPLICATION RANGE OF THIS M ACHINE IS ABOUT THE SAM E
AS WITH M ACHINES WITH TWO ROTATION AXIS IMPLEM ENTED ON THE TABLE.

136

137

CONCLUSION
5-AXES M ILLING OFFERS A LOT OF ADVANTAGES COM PARED TO THE CLASSICAL 3-AXES M ILLING:

A. REDUCTION IN NUMBER OF SET-UP CLAMPING ON M ACHINE

B. A VOIDING OF UNDERCUT FOR MACHINING COMPLICA TED SHAPES
C. BETTER CUTTING CONDITIONS AND BECAUSE OF THIS, LESS WEAR OF THE TOOL
D. BETTER SURFACE QUALITY
THE USE OF FLAT END-M ILLS TO MAKE CURVED SURFACES WILL REDUCE PROCESSING TIM E VERY
MUCH. SOM E WORKPIECES M AY BE MANUFACTURED MORE PRECISELY BY THE RIGHT CHOICE OF THE
ANGLE OF CUTTER RELATIVE TO WORKPIECE AND ALSO BY SELECTING AN APPROPRIATE PROCESSING M ETHOD.

THERE ARE HOWEVER SOM E DISADV ANTAGES:

A. HIGH PRICE OF 5-AXES MACHINE

B. MORE POWERFUL CNC CONTROL IS NECESSARY
C. ADDITIONAL ROTATION AXIS CAUSE ADDITIONAL POSITION ERROR
D. THE HIGHER CUTTING SPEEDS ON THE M ACHINE AXIS FOR THE SAM E FEED
E. PROGRAMMING IS ONLY POSSIBLE WJTH SPECIAL PROGRAMMING TOOLS SYSTEM .

PROGRAMMING OF 5-AXES IS STILL A VERY COM PLEX BUSINESS. THE SIM ULATlON OF OPERATIONS AND DETECTION
OF COLLISION IS VERY DIFFICULT. THE PURCHASE OF A 5-AXES MACHINE MUST BE PRECEDED BY A PROFOUND STUDY
OF THE RANGE OF PRODUCTS WHICH HAVE TO BE MACHINED. BECAUSE OF THE SPECIAL CONSTRUCTION A SPECIFIC
5-AXES M ACHINE WILL BE M OST APPROPRIATE FOR A SPECIAL SET OF WORKPIECES. SO M ACHINES WITH A TURNING
TABLE ARE FOR EXAMPLE VERY GOOD TO PRODUCE ROTATIONAL WORKPIECES SUCH AS COM PRESSORS. HOWEVER
FOR THE PRODUCTION OF LARGE STRUCTURAL ELEM ENTS IN AERODYNAM ICAL INDUSTRY A MACHINE WITH A
SUITABLE TOOL SPINDLE IS TO BE PREF'ERRED.

138

OVERVIEW OF DIFFERENT FIVE AXIS

MILLING APPLICATIONS
- POSITIONING:
*DRILLING, TAPPING, BORING AND FACING UNDER ANY ANGLE
IN ONE SET UP
*SMALL NUMBER OF BLOCKS IN CNC PROGRAM (+/- 100 BLOCKS)
*MANUAL PROGRAMMING POSSIBLE
*5 AXIS MACHINE WITH TWO AXIS CNC CONTROL

139

OVERVIEW OF DIFFERENT FIVE AXIS

MILLING APPLICATIONS
- CONTOURING:
*
*
*
*
*

COMPLEX SURFACES, ELECTRODES FOR EDM DIE-SINKING

DOUBLE CURVED SURFACES
VERY LARGE CNC PROGRAMS (+/- 100,000 BLOCKS)
IMPOSSIBLE WITHOUT GOOD CAM SYSTEMS
5 AXIS MACHINE WITH 5 AXISCONTOURING CNC CONTROL IS REQUIRED

140

SELECTION OF MACHINE AND CNC CONTROL

- MACHINE CONFIGURATION:
AXIS CONFIGURATION
RANGE OF ROTATIONAL AXIS MOTION
ACCURACY
MEASURING SYSTEM
SPINDLE SPEEDS
POWER FEEDRANGES
TOOLCHANGER
- - CNC CONTROL
MUMBER OF SIMULTANEOUSLY CONTROLLED AXES
MEMORY
BTR FEATURE (BEHIND TAPE READER)
DATA TRANSFER SPEED
PC KEYBOARD
DIRECT NUMERICAL CONTROL (DNC)
USERFRIENDLYNESS (GOOD MORNING !!!)
PROCESSOR SPEED
SELF DIAGNOSIS
141

- TOOLING FOR THE MULTI-AXIS MACHINES

SMALLER AMOUNT OF TOOLS STANDARD TOOLS
LESS FTXTURES
-CAD/CAM SYSTEM FOR PROGRAMMING
MULTI-AXIS MACHINES
MUST BE ABLE TO GENERATE CORRECT 5 AXIS
TOOL PATHS POSTPROCESSOR.
PROGRAM VERTFICATION AND COLLISION DETECTION

142

DEFINITION OF MACHINE TOOL

any stationary power-driven machine that is used to shape or form parts
made of metal or other materials. The shaping is accomplished in four
general ways:
(1) by cutting excess material in the form of chips from the part;
(2) by shearing the material;
(3) by squeezing metallic parts to the desired shape; and
(4) by applying electricity, ultrasound, or corrosive chemicals to
the material.

143

Computer-aided machining
Computer numerical control (CNC)
Adaptive control
Machining centers
Computer-aided design and
computer-aided manufacturing (CAD/CAM)
Robots
Flexible manufacturing system (FMS)
Computer-integrated manufacturing

144

Nonconventional methods of machining

Electrical methods of machining
Electron-beam machining (EBM)
Electrical-discharge machining (EDM)
Electrochemical machining (ECM)
Ion beam machining (IBM)
Laser machining (LM)
Plasma arc machining (PAM)
Other methods of machining
Ultrasonic machining (USM)
Chemical machining (CHM)
Photochemical machining (PCM)
Water-jet machining

145

LATHE

146

LATHE CUTTING TOOL

147

CUTTING TOOL TYPES

148

BORING ON A LATHE

149

MILLING MACHINE

150

MILLING TOOLS

151

TOOL HOLDING

152

SPRING COLLETS

153

FACE MILLING

154

DRILLING MACHINE

155

THREAD TAPS AND DIE

156

BAND SAW

157

METAL CUTTING THEORY

158

Build up edge formation for steel cutting at about 50m/min

159

BUILD UP EDGE

The build up edge is periodically deposited on the part

160

GRINDER

161

SHEAR

162

NOTCHER

163

PRESS BRAKE

164

SHAPER

165

SLOTTER

166

PLANO MILLER

167

168

Kinematic Modeling of Machine Tools

Structural Modeling of Machine Tools
Thermal Modeling of Machine Tools
Modeling Machine Tool Dynamics

169

170

171

The figure illustrates a Hexapod-type

machine tool of the Stewart platform, which
is one of the most typical parallel mechanism
structures. It has six telescoping struts, each
of which is connected to the base by a 2-DOF
(degrees of freedom) joint. The other end of
each strut is connected by a 3-DOF joint to
the platform, where a machine spindle is
installed. The 6-DOF control of the spindle
position is possible.

172

Motion Accuracy: On a parallel-link machine,

the position of the spindle head is indirectly
estimated from the rotational position of
servo motors. Therefore, for its high accuracy
motion control, it is crucial to accurately
identify all the mechanical parameters such
as the length of struts or the position of joints.
Furthermore, the deformation due to the gravity
is a critical issue for parallel-link machines.
In particular, when it is driven near the edge
of its workspace, the motion accuracy gets
considerably worse than that of conventional
serial-mechanism machines.
173

Stiffness: Since the spindle unit is supported

only by struts, the stiffness against the
disturbance, such as a cutting force,
is not as high as that of serial-mechanism
machines. Currently, in many cases,
parallel-mechanism machine tools are used
only for the machining of soft materials,
such as an aluminum alloy.

174

A Double Ball Bar (DBB)

Test on a Parallel Mechanism
Machine Tool for Calibration

175

RULED SURFACE MILLING

-High metal removal rate
-Smooth surface
-However large undercut in no special
algorithms are use

176

Large Overcut

Special ruled surface milling algorithm

Tool end in plane of tangent and

Normal to border curve a

Move tool along Nm

To minimize overcut

Reduced
overcut

Tool end in plane of middle between a and b

177