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Secretsof5AxisMachining PDF
Secretsof5AxisMachining PDF
I S B N 9 7 8 - 0 - 8 3 1 1 - 3 3 7 57
ttn
ril
llillffill
Secrets
ot S-Axis
Machining
by KarloApro
IndustrialPress,Inc.
NewYork
Libraryof CongressCataloging-in-Publication Data
Apro, Karlo.
Secretsof s-Axis lvlachining/ Karlo Apro.
p. cm.
Includesindex.
rsBN 978-0-8311-3375-7
1. l4achinetools--Numerical control.2. Machining.I. Title. IL Title:
Secretsof 5-AxisMachining.
TJ11B9.A68 20OB
671.3'5--dc22
2004027254
IndustrialPress,Inc.
989 Avenueof the Americas
New York,NY 10018
FirstPrinting,August,2008
STATEMENTOF NON-LIABILITY
No liabilityis assumedby the author or publisherwith respectto use of information
contained herein, includingfor any loss of profit or other commercial,special, or
incidental damages.While every reasonableprecaution has been taken in preparing
this book,the author and pubiisherassumeno responsibility for errorsor omissions.
Publicationof any data in this book does not constitute a recommendationor
endorsementby the authoror publisherof any patent,proprietaryright, or product,
10 9 B 7 6 s 4 3 2
Printedby ThomsonPressIndiaLimited
Dedication
Thisbookis dedicated,
in lovingmemory/to my motherPiroska.Shetaughtme
the meaningof hardworkandperseverance. Althoughshepassedawaybeforethe
completion
of this book,her spiritcontinues
to livewith me.
Acknowledgements
C h a p t e r 2 !K n o w Y o u r M a c h i n e . . . . . . , , , . , . . 1 3
l4ultiaxisl\4achineConfigurations .........74
T a b l e / T a b l e M u l t i a x i sf l44ai cl lhi ni nge s . . . . . . . . . . . . . . 1 8
I \ 4 a c h i nReo t a r yZ e r oP o s i t i o(nl v l R Z P ) ......21
N e s t i nPgo s i t i o n s , ............26
RotaryTableDynamicFixtureOffset . . . , , , , , , , . . . . . 27
H e a d / T a b l e M u l tl i4ai xl liisnl vg l a c h i n e s . . . . . . . . . . . . . . 3 1
H e a d / H eM
a du l t i a x i s l v l il l4l a
i ncgh i n e s . . . . . . . . . . . . . . 3 6
F i n d i ntgh e P i v o D
t istance ......37
4 - A x i ls\ 4 a c h i n e s .............3S
Genemll4aintenance
& Issuesfor 14ultiaxis
lYachines. . . 40
I\4illing
l4achinesWith Five-or l.4ore-Axes.
. . . . . . . . . . . 43
C h a p t e r 3C: u t t i n g S t r a t e g i e s . . . . . . . . . . . . . . 4 5
Chapter4r Indexing MultiaxisToolpaths . . . , .49
i I n d e x i nl vgl e t h o d s ........,,.51
G
H o wC A D / C A |SVyI s t e m sH a n d l eI n d e x i n gW o r k . . . . . . . . 56
O*= MachineCoordinateSystems. .
Home Position . .
lulachine
ActiveCoordinateSystem . . ,
RotaryCenterPoint , .
I\4achine 60
CAD/CAMSystemOrigin . . . 60
SynchronizinglYachineand CAD/CAMcoordinateSystems .
Feedrates. .......,,72
P o sPt r o c e s s o r s . ....,........76
T o oTl i pC o n t r o l . .............90
C o l l i s iCoonn t r o l .............93
A d d i t i o nMaLl r l t i a x i s I s s u e s a n d C o n t r o l s . . . . . . . . . . . . , 9 8
D o v e tE
a fi lf e c t . ....,.......98
C u t t i nDgi r e c t i o n ..........100
I v l u l t i aRx o
i su g h i n g . ........101
C h a p t e r TM
r achineSimulation....,..,,..,1O3
G - c o d e S i m u l a t i o n V e r s u s C A M S i m u l a t i o n . .1. 0. ,5. . . . .
C o n f i g u r i n g V i r tM
Lar ac lh i n eFso r S i m u l a t i o n . . . . , . . . . 1 0 5
VirtualMachineBuilding...,,......,...106
T h eS k e l e t o n .....106
C o m p o n e nv tss.l t 4 o d e. l.s. ...,......I07
M a c h i nSei m u l a t i Ionnt e r f a c e. s .........116
U s i nM
gachin
S ei m u l a t i .o, n. . ...,,....7I7
LongbeforeCNCcontrollersappeared,4-5-6-12-and more-axismachines,referred
to as multiaxismachines,were beingused.Ihe individualaxeswere controlled
mechanically through leversridingon cam plates.Some machineshad more than 12
cam plates,controllingnot onJytool/tableand rotary motions,but also clamprngand
unclampingof work-holdingfixtures.Thesemachineswere cumbersomeano atme
consumingto set up, but they were perfecUysuitedfor mass production.
N.ext,-the
first.rudimentaryCAD(ComputerAidedDesign)/CAM (ComputerAided
lYanLrfacturing)systemswere devejoped.At first, these softwaresoluiionswere
introducedby the same companiesthat developedthe controllers.Soonafter,
enterprisingindividLrals
wrote their own CAD/CAI4 software.Thisjump in tecnnorogy
was huge becauseit allowedengineersto draw their parts in a CADprogram,
generatea toolpathin the CAMsystemt genericlanguage,and then translateit into
multipleG-Codelanguagesquickt, usingthe appropljatepost processor.
Ivlultiaxis
machineswent througha similarprocess,but becausethev were more
complicaled,this processlook longer.First,Ihe machineswere expensiveto
purchaseand maintain, and harder to program,Only large aerospacecompanies
had the need, the money,and the personnelto handle multiaxisapplications.Some
companieskept their own processescloselyguardedin order to gain an advantage,
Many softwarepackageswere born out of necessity- in order to solve specific
applicationchallenges.Software,in general,is alwayson the very leadingedge of
technology- pushingthe limits of softwarepossibilitiesand hardwarerestrictions.
Common Misconceptions
Most peopleassociatethe word "s-axis" with complicatedmotions such as those
for the inductionpump illustratedin Figures1-1 and 1-2, and the programming
techniquesneeded,This view is reinforcedby visits to any industrialtrade show
to see both machinebuildersand CAD/CAMvendorsshowinooff their most
complicatedcreations.
Historyof s-AxisMachines
common MisconceptionrI don't ilo enough S-axis work to warrant
a S-axis machine.
The abovestatementswere true in the past, but not any more. If you currenfly
own a CAD/CAMsystem, there is a good chanceyou already have s-axis
positioning capabilities.
MostcAD/cAMsystemsincludethesecaDabilities in their
basepackage.Manytimes, it is just a matter of trainingthat is neededto get up
a n d r u nni n g .
Historvof s-AxisMachines
If you do a lot of simultaneousmultiaxiswork, the price of the CAD/CAMwill be
only a smallfactor.Moretrainingwill be needed,but you will be ableto charge
almostdoublefor your hourlymachinetime. The'hardto use'paft alwayscomes
down to training - was it easy to learn how to operateyour first CNCmachine?
Accuracy
Everytime you move a workpiecefrom one fixture to another,there is a risk
of misalignment- either during the set-up itself or during operation.It is easy
to build up (stacked)errors betweenmachinedsurfaceswhen they are milled
in multipleset-ups.The use of indexingrotary tables, or dedicatedmultiaxis
machines,as shownin Figures1-11 and 1-12, allowsprecisemovementof short,
rigid, high speedcutters for the best cutting engagement.More aggressivecuts can
then be taken, with higher RPMand feed rates, while the highestlevelsof accuracy
are maintained.
Historyof s-AxisMachines
Figure 7-72 Dedicated dual-rotary machine set-up.
10 Secretsof s-AxisMachining
Open New Possibilities
some partsare impossibreto cut on a 3-axismachine.other partswourdtake
too many set-upson a 3-axismachineto be profitable.Onceyour shopgets
comfortablewith indexingwork, you will be able to start machiningpart; suchas
thosein Figures1-15, 1-16, and 1-17, usingsimurtaneous murtiaxismotions,and
openyour buslnessto many new possibilities.
Figures 7-75, 7-76, and l-t7 More examples of parts that require simultaneous
cutting motions.
Historyof s-Axisl\ilachines 11
Know Your Machine
CNCcontroller capabilities
The controlleris the brainof the machine.Data handling,availableon-
boardmemorysize,and dynamicrotarysynchronization controls,are
someof the thingscontrolledhere.
The lllustrations
in Figure2-1 showsomeof the varietythat existsin the machines
that make up the CNCmanufacturing industry.
13
Figure 2-7 Typical arrangements of multiaxis CNCmachines.
TU
Figure 2-2 The spindle head and the spindle quill move along parallel axes.
14 Secretsof s-AxisMachinino
The terms multiaxisand s-axisare often usedinterchangeably and theseterms
can be confusing.The widelyrecognized term in the industryis 5-axis,but it is
misleadingbecauseg-axisstandardpossibilities exist - withoutaddingadditional
sub-systems.In addition,a 4-axismachineis alsoconsidered to be a multiaxis
machine.Despitethe title of this book,the more accurateterm multiaxiswill often
oe useo.
KnowYourMachine 15
Unfortunately,different machinebuildersabide by this standardin differentways.
Some buildersallow the end user to changethe machine'srotationaldirections
or behavioron the fly. Third-party rotary devices,as shown in Figure2-3 and
elsewhere,can be purchasedand mounted on a machinein a variety of ways, The
end result of this flexibilitycan causetwo machines,of the same make and model,
to have completelydifferent S-axisbehavior.
16 Secretsof s-AxisMachining
MachineRotary Zero Position (MRZP)- On multiaxismachines, machinerotary
zeroshownin Figure2-4, is at the intersection
of the rotary/pivoting
axes.This
pointmaybe unreachable by the machine.
KnowYourMachine 17
Whensettingup/ operating/and programmingmultiaxismachinesit is essentialto
maintainthe properrelationship
betweenthe machinezero position(MRZp) and
the programzero position(PZP).
lYultiaxis
millingmachinescan be organizedfurtherinto 3 major machinetypes:
Keepin mind that the focusof this book is milling,althoughthe line betweenthe
mill and the latheis blurringmore and more everyyear.Thereis a new breedof
multi-taskingmachinesavailablethat can do millingand turning,and thoseare
calledMill/Turnmachines.
18 Secretsof s-AxisMachining
oneof the rotaryaxes.somewill haveunlimitedrotary motionon the otheraxis.
Someevenhavethe capabilityto spinthe work,as a lithe woutd.
Table/Table machinesare the mostcommontypesof murtiaxismachines.Most
peoplewill enterthe s-axisworldby purchasing-a
single-or dual-rotarydeviceand
boltit to their3-axismillingmachine
KnowYourMachine 19
Figure 2-8 Third-pafty single rotary mechanism and tailstock, fastened to the
table of a standard 3-axis CNC milling machine.
After machiningone side of the work piece it is possibleto index the rotary unit
to machinethe secondside, and so on. This type of work is called indexingor
positioningwork. Some manufacturersuse specializeddual rotary mechanisms.
such as the one shown in Figure2-9, which is designedfor machininginternal
combustionenginecomponents.
Evensmalldiscrepancies
will magnifyerrors.furtherawayfrom this machinerotary
zero point.
KnowYourl\.4achine 21
Here are the steps to be taken:
1. Level the table by "zeroing" the indicator on either side of the table, as
shown in Figures 2-1O and 2-11
Figures 2-7O and 2-77 Method of checking the level by dial-indicating both sides
of the workholding table
Figure 2-72 Setting the dial indicator to zero before checking the level of the
table.
Secretsof s-AxisMachining
2. Find the XY zero, using the dial indicator, Zero xy and A at this point, as
shown in Figure 2-13,
Figure 2-74 After rotating the A axis through 90 degrees, touch the outside
diameter of the table with the dial indicator.
KnowYourMachine
4. Rotate A-axis through 18Odegreesfrom the previous position and make
sure the indicator reads zero on the other side.
Figure 2-75 After rotating the A axis through-90 degrees,touch the outside
diameter of the table with the dial indicator'
5. Move the Z-axis in minus direction the radius of the rotary table and set
up a gage tower. The gage tower is used to set all the tool length offsets
to z=o.
Figure 2-76 A gage tower is built to represent the MRZPto allow tool length
offsetsto be set.
24 Secretsof s-AxisMachining
This location is the machine's rotary zero position (MRzp), as illustrated in
Figure 2-17,
Figure 2-77 The rotary zero position of the machine, as establishedby the
outlined procedure.
Note that the intersectionof the dual rotary center lines is abovethe table in
the examplegiven.This locationwill be differentfor every machine,even from
the same manufacturer.It is imperativethat this positionbe checkedregularry,
especiallyaftera heavyworkloador a crash,Smallmisalignments can causeiarqe
errors becausethe tool positionis measuredfrom this intersectionpoint.
F o re x a m p l ec: 9 0 c 5 4 x 0 . y 0 . A 0 . c 0 .
Some CAMsystemscall this positionthe World Zero, Master Zero, or the Origin.
The main thing to remember is to draw the part in the same specificposition
relativeto this World Zero as it sits on the machine,relativeto Machine Rotary
Zero Point.
Nesting Positions
Nestingpositionsare widely used for positioningwork. These positions,shown in
Figure2-19, are temporaryActive Coordinate Systems and are typically set in
relationto different faces of the part or fixture face, tooling ball, or dowel pin.
Secretsof s-AxisMachining
The advantageof using these Locar.coordinate systems is that you can easiry
followthe programon the controller,s displaysc.eenbecausethe absojute
valuesshown there will reflectthe valuesrelativeto each locally-nestedposition.
Z+1.000,for examplewill be 1.000(inch)abovethe part face.
Despitethe fact that cAM systemsa use different naming conventionsfor their
coordinatesystems/they alr handrethe rocarcoordinatesystemin a simirarway.
Some.ofthe names used by_CAD/CAMsystems include:p'art Datum, Active
Coordinate System, Local Coordinate System, System View, and Tool plane
with an Origin.
The Solution
If the operatordoesn't have accessto the cAM system/ and is unableto match
the cAl4's part positionon the machine,an option on the machinewi[ be needed
to compensate for the discrepancy
betweenthe two positions.This optionis called
KnowYourl\y'achine
Rotary Table Dynamic Fixture Offset (RTDFO).
When the Rotary Table Dynamic Fixture Offset function is activatedon the
controller,the Program Zero Point (CAM datum) is offset to correspond
with the set fixture offset amount, as shown in Figure2-20. This offset is the
distancebetweenthe center of rotation (MRZP) and the Part Zero Point (PZP)
and it must also take into accountthe angle of the rotary table. This function is
convenientbecausemultiple-facemachiningcan be executedby setting one point
as the referencewhen machininga complexworkpiece.
KnowYourlvlachine 29
ActivatinoRTDFO:
-
00001 { P,ROGT?Ar, ZERO ) 00001 { P.eoGr?Ai,- cLoNE2 )
( D]TE A2 ]i A7 TINE 07:22 ) ( DA?a - O2-i1-07 TIME - A7:22 )
G21
c0 G17 G40 cac c90 G94 G9a G0 c17 G40 G80 G90 c94 G98
I rooL 3) D.aa. oii. - 3.1 ,,rN_ 3) Dra. ( laoL 31 Dra. a!F. 3:L LEN- 31
( G13.4 G5 Pl0O00 ) ( c43.1 G5 P1A0O0 )
T3t T3t
M6 M6
M69 M69
30 Secrets
of s-AxisMachining
Head/Table Multiaxis Milling Machines
As their name suggests,these machineshavea rotarytableand a tilting head.
Figures 2-23, 2-24, and 2-25 Example of Head/Table multiaxis milling machines,
which have rotary tables and tilting spindle heads.
KnowYourl\y'achine
Head/Table machinesare arguablythe most capableof the three groups
illustratedand can machinelarge,heavyparts.On some machines,the rotarvtable
can be supportedby a steady rest and it rotatesthe paft only around its own axis.
The pivotingspindleheadcarriesthe weightof the tool. It needsto be capableof
handlingthe cuttingpressuresas it is manipulating the tool.
On a Bostomaticcontroller,
for example,this resultis achievedby addingtwo lines
of code.
Figures 2-27, 2-28, and 2-29 Examples of machines with spindles at the zero
Dosition,
The sum of the Pivot Distance and the Gage Length is the Rotary Tool control
Point (RTCP), which has to be triangulatedfor every s-axis positionof the
toolpath.Figures2-30 and 2-31 show examplesof B90 rotation with and without
RTCP.
Figure 2-3O Example of 890 rotation without RTCP,and Figure 2-37 890 with
RTCPactive.
KnowYourMachine
The machine'slinearaxesalso haveto movealongthe X and Z axes in orderto
keep the tool tip stationaryin spaceas it executesthe pivoting B90 motion. CAM
systemswill makethe necessarycalculations during"post processing.,,Some
machineshavethe abilityto calculatethe necessarymotionsautomatically, based
on the offsetsshownin Figure2-31, capturedin the machinecontroller,s reqistries.
=
TANCE
PIVOT
COMPOFFSET
rbor-rr'rerrt
Fanucexamole:
G43.4, G43,5 s-AXIS ROTARYTOOL CENTERPOINT CONTROT(RTCP)
G49;
G43.4 . . . Toolcenter point function (Type 1) ON
x,l ,z, . . . (G90) The coordinatevalueof the end pointof the tool
center movement
(G91) The travel amount of the tool center
B,C . . (G90) The coordinatevalue of the rotary axes end point
(G91) The travel amount of the rotary axes
H . . . Tool length offset number
c49 . . Toolcenter point control function (Type 1) OFF
Example:
G90G00G54x0, Y0.80. C0.; . M o v e sX , t , B, C to PzP
s5000M03
G43. 4 zL . H01; . Activate RTCP. Positionsthe tool tip at Z+ 1.000
while Z axis positionis offset by offset data set for tool length
offset number 1.
Head/HeadMultiaxisMilling Machines
All the rotary/pivotinomotions are executedby the spindlehead of the machine.
These machinescan be both verticaland horizontal,and they have limited
motion. Some machinescan changeheads,not just tools. Headscan be straight,
g0-degree,nutating,or continuously indexing.Someexamplesare shownin Figure
z- 5+.
KnowYourl\,4achine 37
Figure 2-36 Touching the dial indicator plunger is eased by having a wide, flat
top on the plunger.
Do not move the machineon the X axis. Moveonly on the Y and Z axes. Move
to a safe point on the Z axis, and rotate the A axis through 90 degreesinto a
horizontalorientation.Next, move on the Y axis in the plus and on the Z axis
in the minusdirectionsuntil you get to the positionshownin Figure2-37.
38 Secretsof s-AxisMachining
Youshouldhavethe followingvalueshandy:
Z maximum
Z minimum
GL - Gage Length
R - Dowel pin radius = .5OOO
Formula to calculate Pivot Distance:
PD=Zmax-Zmin-GL+R
4-Axis Machines
If a third-pafty,singlerotary mechanismis placedon a 3-axismillingmachine,it
becomesa 4-axismachine.The most oopulardedicated4-axismachinesare the
horizontaltypesshownin Figure2-38.
Somecommonoroblemsinclude:
KnowYourMachine 41
Figure 2-47 Indicating run-out.
The machinetypes describedin this chapter are built by many different machine
buildersin a variety of sizes,shapes,qualities,and prices.The quality of a machine
will be best highlightedwhen fast. simultaneous, multiaxismotionis beingused.
A good-qualitymachinewill executethese motions quickly and repeatedly,in a
smooth synchronizedway, without one rotary axis waiting for anothel and without
backlashor vibration.The rotarymechanisms will haveminimalrun-out,and the
rotary centerlineswill align precisely.Cheapermachinesmay execute positioning
movementswell, but will executesimultaneous motionspoorly.
42 Secretsof s-AxisMachining
Milling Machineswith Five or More Axes
lVostmachineswith more than five axes are built for specificmanufacturing
applications,Some examplesincludethose shown in Fioure2-42:
KnowYourMachine
E A simpleexampleof sucha subroutineis an M06,whichcausesa tool change.
Observecloselywhat happenson any machinewith an automatictool-changer:
the machineslidestravel to pre-determinedlocations;the tool-changecarousel
advancesthe chosentool; a little trap door may open, dependingon the
machine;then a swing-armwill exchangethe tool betweenthe spindleand the
carousel. This whole choreographyis just one of many internal macros,ready
to be activatedby a simple code like M06. On multiaxis machines,many more of
these internal macrosare available.Most of the time, the macrosneed to work in
svnchronization,
Do you have to use existing fixtures or can you make your own?
CompareMachines
If more than one machineis availablefor the job, some comparisonsshouldbe
made.Amongessentialchecksare: work envelopelimitations,maximum RPIY,
feed-rates,and controllercapabilities.
CuttingStrategies
Indexing Multiaxis Toolpaths
Figure 4-7 Images showing how one part can be cut from many different angles,
without being removed from the fixture.
49
Figure 4-7a Images showing how one part can be cut from many different angles,
without being removed from the fixture.
Secretsof s-AxisMachining
The conceptmay be simple, but it allows for the manufactureof very complex
parts with precision,like the samplesshown in Figures4-2 and 4-3.
Indexing Methods
There are many different indexingmethods,and they can pedormed with
equipmentas simple as a manually-operated,custom indexingfixture. Third-party
autonomousrotary devicesalso are available,which will executepre-programmed
indexingsequencesat every cycle.The cyclescan be activatedmanuallyor through
a dedicatedM-Code.If one of these methods is used, great care must be taken to
synchronizethe manual operationswith the Nc-code,Ample opportunitiesexist to
make a mistakewith these methods.
IndexingMultiaxisToolpaths 5'l
The best method is to use fully-integrated. third-party, rotary devices,which will
executerotary commandsdirectly from the Nc-code.For these methods,the rotary
pivot center must be preciselylocated(as describedin Chapter2).
52 Secretsof s-AxisMachinino
Figures4-8 and 4-9 show some examplesof dedicatedmultiaxismachine,rotary
mechanisms.
Figures 4-8 and 4-9 Some examples of dedicated rotary machine components.
Figure 4-7O Spindle heads on some machines are designed to be straight, set at a
specific angle, or even adjusted steplessly to various angles.
IndexingMultiaxisToolpaths
Othermachines,usedmainlyin the medicaland aerospaceindustries,are designed
to indexand hold the part with grippingaxeswhile machining.Examplesof these
types of machinesare shown in Figures4-LL and 4-I2.
Figures 4-77 and 4-12 Some machines are designed to index and hold the part
during machining.
IndexingMultiaxisToolpaths
How CAD/CAMSystems Handle Indexing Work
BeforediscussingCAD/CAMsystem applications,it is importantto establishsome
of how CNCmachineswork.
core understanding
tz
Figure 4-75 Positioning two fixtures with parts on a machine and assigning
individual local coordinate systems.
56 Secretsof s-AxisMachining
Machine Coordinate Systems
Machine Home Position
IndexingMultiaxisToolpaths 57
Figure 4-76 Multiplenestingpositionson a tombstonefixture.
t
\
Figure 4-78 Central coordinate system on a single part.
lndexingMultiaxisToolpaths
Usinga singleActive Coordinate System requiresthat only one positionbe
indicatedon the machine.This approachsimplifiesthe processand lessensthe
possibilityof error.
So far it has been establishedthat every machinehas its own Home Position,
which is its center of the universe.Every localcoordinatesystem is a relative
locationin that universe.Also, the intersectionof the rotary axis, commonly known
as the Machine Rotary Center Point, is a relativelocationin that same universe.
and its positionis stored in the registry.
CAD/CAMSystem Origin
EveryCAD/CAMsystem also has its own universe.They all have a world zero,
Master Coordinate System, System Origin, and so on. Just like machinetools,
all these locationsare called by different names.One thing you can be sure of -
noneof them will havethe same Home Position as any other machine.The job of
a CAD/CAMuserand CNCmachineprogrammeris to alignthe worldsof both the
machinesand the CAD/CAMsystems.
If the One Zero method - where the local coordinatesystem on the machine,
which is the Machine Rotary Zero Point - is in use, it is possibleto simply
match the CAD/CAMSystem'sWorld Zero with that location.The part must then
sit in the same relative locationand orientationfrom the Machine Rotary Zero
Point of the systemand the machine,as seenin Figure4-19.
Figure 4-2O The relationship of the part zero to the Machine Rotary Zero point.
IndexingMultiaxisToolpaths 61
,
"p{
ffe
,
Secretsof 5-Axis[,4achining
Figure 4-22 Complete Machine Simulation.
IndexingMultiaxisToolpaths
Figure 4-23 Virtual -axis horizontal machine for simulation purposes.
o4 Secretsof s-AxisMachining
SimultaneousMultiaxisToolpaths
The illustration
in Figure5-1 showsa 2-axismachinecuttinga patternonto a
bowlingball.This machineonly has a tilting B and a rotatingC-axis.Thereis no
Z axis. Instead,that motion is controlledby a softwareM code, which has an ON
and OFFstate - either loweringthe tool onto the part, or lifting it to its reference
Dosition.
65
c01 22.0000 F90.
x - 5 . 5 A 2 8 8 0 . 0 0 0 F 5 0.
GOO25.
SimultaneousMultiaxisToolDaths
An exampleis the spiralbevelgear shownin Figure5-6, whichwould normallybe
producedon a specialgear-cuttingmachinein an automobileplant.
02000
G91G1Z-.1E50.
x2.22-.1C60.85. (4-axis simultaneous motion)
x - 2 . 2 2 . 1 C - 6 0. B - 5 .
M99
03000
M98 P2000 i,3
G91G002.3
zr.
c72.
lt-L.
M99
Secretsof s-AxisMachining
This last exampleis very simplistic,but with somecreativeuse of branching/looping
logic.Someshopshave usedthis techniqueto producevery complexparts.
CADsystemshaveevolveddrastically
and, as a result,it is possibleto designand
manufacture
ever-morecomplexparts like the examplesshownin Figure5-7.
Simultaneous
MultiaxisToolpaths 69
Figure 5-7 Examples of parts produced on multiaxis milling machines, including
turbine blades and rotors, impellers, pump components, brackets, and manifold
covers.
Figure 5-9 Example of part being placed far away from MRZP.
Simultaneous
MultiaxisToolDaths 71
In Figure5-9 it should be noted that the B-axis move is much longerthan the
C-axismove, even though the angularvaluesare the same. The reason,of course,
is that the circumferencesare widely differentfor the B and C motions. High-
quality machineshandlethese kinds of unevenrotary motions better than lower-
quality machinesbecausethey synchronizethe two rotariesto arrive at the same
point, while maintaininga constantfeedrate.CAD/CAMsystemscan also control
feedratesby using Inverse Time Feedrate output. A more detailedoverviewof
these controlsis includedin the Feedratessectionof this chapter.At this point, it
is sufficientto know that it will be much better to placethe workpiececloserto the
same rotarydiametersof the specificmachine.as shownin Figure5-10, especially
if a third-partydual-rotarytable,or a lesserqualitymultiaxismachineare in use.
Figure 5-7O The part is placed close to the Rotary Zero Point of the machine.
Feedrates
On a 3-axis (non-rotary) machine,there is no need to specifya feedratemode
becausethese machinesall operatein the units/time mode.
72 Secretsof s-AxisMachining
Figure 5-77 A diagonal groove is machined by moving both tabte stides
simultaneously using linear interpolation,
Figure 5-72 Circular interpolation is used to move the workpiece in a circutar path.
SimultaneousMultiaxisToolDaths
A planarcirclecut usinga c3 r-5. F10. commandis illustratedin Figure5-12.
The resultingmotionappearsto be a true circle,but it is not. Any machinethat has
the standardthree XYZlinearaxescannotcut a true circle;only an approximate
one.The slideson these machinescan move only in straightlines.Therefore,in
orderto generatea circularpath,the controllerwill haveto interpolatea circular
move by breakingthe programmedcircleinto a numberof straight-line segments.
On most machines,the circulartolerancecan be set from insidethe control
parametersettings.The largerthe sizeof straight-line segments,the lessaccurate
the circleswill be. A smaliernumberwill resultin more accuratecircularcuts.
The exampleshownin Figures5-13 and 5-14 has only one rotary motioncombined
with X and Z linearmoves.
Simultaneous
Multiaxis
Toolpaths
Lookingat the two illustrations in Figures5-13 and 5-14, it is possibleto observe
and imaginethe differencein travel distancesbetweenthe tool tip and the rotary
centerpoint of the head.To maintainthe programmedfeed/minuteon the tool tip,
the center of the rotary spindlehead needsto move very quickly.This scenario
can be comparedto runnerson a track. Runningin the insidelaneof the track
coverslessdistancethan runningon the outsidelaneof the track.The tool tip is
the runneron the insidelane,and the centerofthe rotaryis runningon the outside
t an e .
In short, the machineshould not be instructedto move from the current positionto
the destinationat X units per minute.Instead,it shouldbe told to movefrom start
to destination,in X amountof time, in a smoothinterpolated motion,on all the
axes involved.On Fanuctype controls,G93 signifiesthe staft of the inversetime
mode.Theremust be an F commandat the end of every line containinga G1, G2
and G3 code.The Inverse Time mode will not affect rapid G0 moves,
Inverse Time Feedrates were widely used in the early days of NC, but today
many modern CNCcontrollersare capableof parsingstandardfeedratesinto
inversetime and vice-versa.(A parseris a compileror interpreter).Usually,an
inversetime smoothingalgorithmis incorporated into this featureand it can be
parametersetting.
enabled,or disabled,in the controller's
Post Processors
CAD/CAMsystemsgenerates-axis vector lines along 3D paths.The 3D paths
representthe tool motion as it followsthe pattern being cut. The vectors represent
the individualtool axis directions(IlK vectors)as the tool followsthe 3D (XYZ)
pattern. Everyvector is representedby a line of code, and during toolpath creation,
a resolutionof these vectors can be specified,either by definingthe minimum
angulardifferences,or the linear distancesbetweenvectors,This informationis
writtenin a genericlanguage.Depending on the CAD/CAMsystem,the language
may be calledAPT,CLS,NCI,and others.Machinetool controllersdo not speakor
understandthesegenericlanguages, howeverthey do understandmany different
languages and dialects.
76 Secretsof s-AxisMachining
to machinethe part. A different post processorwill be neededfor every type of
multiaxismachinein the shoD.
Simultaneous
MultiaxisTooloaths
lYanyCAMsystems handle safe motions betweentwo subsequent.toolpath
operationswith post processors.Thesecontrols retract the tool into a safe
area, and a s-axis machinerepositionsfrom one operationto the next.
Instead of simply retractingto the MachineHome Position,safety volumes
(box, hemisphere,cylinder)can be used for efficienttool retraction.Keepin
mind that an efficienttoolpath doesn't make erratic and unnecessarymotions
- it retractsthe workpieceonly to a minimum safe distance,and keepsthe
cutterengaged,while maintainingall machineaxesin optimumpositions..
lot of effort,
Developinga post processorfor multiaxismachinestakes a "hackers"
talent, professionalism,and perseverance.There are many who are
managingto "make it work,"but a high-qualitypost processoris suppliedwith
detaileddocumentationand user-definedswitches.
In additionto those three major controls,which are definedin more detail in this
chapter,good-quality CAD/CAN4 systemsalso provideadditionalcollision-avoida nce.
This insurance will recognizethe tool'scutteLshank,and holder.Differentavoidance
behaviorscan be invokedwhen any of thesecomponentscomesinto proximitywith
the work-pieceor a fixture. Differentnear-misstolerancescan be assignedto each of
these tool comDonents.
Cut Patterns
Cut Patterns guide the tool along specifiedpaths.These patternscan be simple 2D
or 3D wireframe,or solidprimitives(for example,box, cylinder,and sphere.)Cut
Patterns can also be complexmulti-surface grids.
79
Figure 6-7 Tool motion following a 3D curve projected on to the face of a workpiece.
Figure 6-3 A Cut Pattern is selected to slice the part in any given plane, for
example, patterns 3 or 4.
Figure 6-5 Cut Pattern that is parallel to the bottom hub sutface, while cutting
individual blades.
Figure 6-6 The Cut Pattern for producing a cylindrical-spiral tool motion.
Common SimultaneousMultiaxisToolpathControls
Figure 6-7 Cut Pattern produced by morphing between the two edge curves of
the floor surface.
Figure 6-8 This Cut Pattern is shown by the red 3D curve projected on to multiple
surfaces,
Figure 6-9 Floor sufface being cut by morphing between two 3D curves formed
by the floor's outer edge curves,
Secretsof s-AxisMachinino
Figure 6-7O Cut Pattern parallel to the floor surface as it spirals down each
blade.
Figure 6-77 Racing engine intake and exhaust ports machined with a spiraling
Cut Pattern.
Common Simultaneousl\4ultiaxisToolpathControls
'l
Figure 5-72 Path following a spherical Cut Pattern.
Secretsof s-AxisMachining
Figure 6-74 Axial Cut Pattern on a Figure 6-75 Radial Cut Pattern
turbine blade. on a turbine blade.
Figurc 6-76 Turbine blade's foot sufface cut by morphing the Cut Pattern
between the outer edge of the foot sufface and the blade surface.
Common SimultaneousMultiaxisToolDathControls
Figure 6-77 Cut Pattern following the natural flow of the surface - the grid lines.
Figure 6-78 The Tool Axis can be locked Figure 6-79 The Tool Axiscan be
normal to a plane. In this example, the lockedso that it always intersectsany
Tool Axis will be maintained normal to definedDointon the holderside.
the bottom floor surface of each
individual inseft Docket,
Figure 6-22 The Tool Axis can be forced to fo ow a chain, while spiraling
down an intake or exhaust channel.
Common SimultaneousMultiaxisToolpathControls
6-23 The Tool Axis is controlled by the curves of the top
and bottom surface edqes.
Figure 6-26 Tool axis normal Figure 5-27 Tool axis at a lead angle.
to a surface.
Figure 6-28 Tool axis at a lag angle. Figure 6-29 Tool with side-tilt angle.
Common SimultaneousMultiaxisToolDathControls
Newersystemseven allowdynamicchangesto be madeto the side tilt, or the
lead/lagangles,whilecutting.The examplein Figure6-30 showsturbineblade
machiningin whichthe Tool Axis is dynamically controlled.With this control,the
tool can be providedwith optimum accessto all the featureson the blade in all
staoesof the cut.
90 Secretsof s-Axisl\4achining
Figure 6-37 Generating tool positions on the cut pattern.
Next, they will move the tool to a desireddepth along the ToolAxis, basedon
the Tip Compensation method.
CommonSimultaneousMultiaxisToolDathControls
Forexample,surfacesgeneratedto controla toolpathfor the humanheadshownin
Figure 6-33.
Figure 6-35 The clean core was used to generate the Cut pattern.
CollisionControl
It is a giventhat collisions
or gougesare alwaysto be avoided,so why is collision
control needed?Why aren't all CAD/CAN4 Systemsdesignedto avoid them
automaticallv?
CommonSimultaneous
MultiaxisTooloathControls
The CNCprocessis very good at reproducingshapesand comes in handy for this
application.The challengeis getting these hand-carvedshapesinto the CAD/
CAMsystem. Probingis a common method usedto reproduceports, A probe is a
sphericalinstrumentthat is used to touch the part and record a point in space,
Touchingmany pointswill recordwhat is knownas a pointcloudwhichis a group
of pointsthat roughly representsthe part's shape.If a probe of the same diameter
as the tool to be used is employed,the tool can be guided along the points in this
point cloud to cut the part. An exampleof a shapeto be reproducedis shown in
Figure.5-36, and a close-upof the probe in contactwith the surfacesin Figure
6-37.
Figure 6-36 Probe being used to generate points over the part's surfaces.
Figure 6-37 Close-upshowing contact of the probe with the partb surface.
94 Secretsof s-AxisMachining
In some instances,it may be advisableto use a tighter cutting grid to obtain
a better finish, or to use a different size of tool. In these conditions,it may be
necessaryto transform the point clouds into workablesurfaces.Thesesurfaces
would exist relativeto the center of the probe and, in this situation,it would be
necessaryto lead the tool center on the surface,(the same place where the probe
center was) thus gougingthe surface.
Figure 6-38 Theseport surfaces were generated on the probe's centerline. The
tool center is led on to the surfaces,
CommonSimultaneous
Multiaxis
ToolpathControls vc
Figure 6-39 This probe sutface was generated with a laser scanner that can
represent the true shape of the port,
96 Secretsof s-Axisl\rachining
Figure 6-40 A warped impeller.
. Specifythat cuts should start from the top and work down toward the bottom
of eachblade.
. Specifyuse of a tapered-shankball-nosecutter.
. If the cutter's shank comes within a certain distancefrom the blade,the tool is
instructedto tilt away, either in the lead/lag,or the side tilt directions.
Common Simultaneousl\ilultiaxisTooloathControls
Figure 6-47 A Clean Cut Pattern with dynamic tool axis control.
Not all CAD/CAMsystems providethis amount of control. Some will only allow the
definitionof check surfacesto be avoided,but will not orovidethe meansto avoid
them. Keepin mind that thesecontrolsfocuson collisionsbetweentools.holders,
fixturing,and work-pieces.They will not avoidpotentialcollisionson the machine.
To avoid collisionsbetweenmachinecomponents,like rotary headsor tables.
machinesimulationis needed.That subiectwill be coveredin the next chaoter.
Secretsof s-AxisMachining
EOVETAIL
Figure 6-43 For cutting a spiral sptine, the tool must be moved off center.
The offset amount must changefor each side of the spline,and the offset amount
will dependon the pitch of the spline. Note also that the bottom center of the tool
face cannot be in contact with the minor diameter.
CommonSimultaneous
MultiaxisToolDath
Controls
Cutting Direction
lYostcutters are very sensitiveto the cutting direction.In the 3-axis world, it is
easy to see and define cuts that are conventionalor climbing,but this is not true
when cuttinga multiaxispart.
Multiaxis Roughing
There are many instanceswhere it is necessaryto use long tools for roughing,as
seen in Figure6-47. This is usuallydictated by the part features.Impellersare
a good exampleof this problem.Tall bladeswith small gaps betweenthem force
the use of a long cutter, and these cutters don't perform well with side-cutting
pressures,As the side-loadincreases,these tools will deflect,causingvibration,
chatter,poor surfacefinish, and drasticallyshorter tool life. Multiaxisplunge
roughingis a good way to remove material in these circumsrances.
Plungecuts should not be made to the final depth all at once. Instead, it is best
to plungeonly to a manageabledepth, plungeout one layer,then pick away on
the next one. The cutting pressurewill be along the tool axis. This procedurewill
eliminatetool deflectionand all its negativeside effects.A typicaljob produced
with this procedureis shown in Figure6-48.
Some CAD/CAMsystems also have the ability to look at the shapeof the stock
model and eliminateall air-cutsfrom the toolpath.This ability,combinedwith
plungeroughing,can shaveoff hoursfrom high-volumeroughingoperations.
Plungeroughing is not a simultaneousmultiaxiscut and therefore is a more rigid
cut.
Figure 6-48 This part was cut out of "green ceramic" which gets fired after
milling. The finished component is resistant to abrasive chemicals in high-
temDerature environments.
103
a newrunproven/5-axisprogramblindlyon a machine,is Iike playingRussian
roulettewith the gun chambersfully loaded.UsingmultiaxisCNCequipmentas a
verificationsystemdoesn'tmake sense,and is much more expensivethan using
simulation.But with that said,nothingcan substitutefor the real thing, Evenafter
simulationtests,the first run will alwaysbe exciting.The sights,the sounds,the
feel of the cuts are irreplaceable.Machinesimulationis not a magicbullet,but used
properly,it is an extremely helpfultool.
Realities
Evenwith today'sadvancesin CAD/CAMcapability, many peoplestill manuallyedit
the code created by their CAMsystem.There are various reasonsfor this and some
of those reasonsincludethe followinq:
MachineSimulation 105
If true G-codemachinesimulationis the goal,Vericutby CGTech, is the best
solutionbecausetheir apDlicationsteam has hundreds of years of combinedhands-
on G-codeexperience and is capableof configuringany type of CNC machine,
even entiremachiningcells. The company specializes in reverse-post processing,
meaningthat they start with G-codeand convertit to machine movements, just
like a machine'sCNCcontrollerwould.
SomeCAMsoftwarepackagesoffer multiplemachinesimulationinterfaces.
A few havedirectinterfaceswith Vericut.Anotherpopularchoiceis Machsim
by Moduleworks.The equally-capable Moduleworks in post
team specializes
processorsconfiguredto produce both the simulationand the G-codeoutput.
Virtual MachineBuilding
It is not necessaryto virtuallybuildan entiremachineincludingthe chip conveyor,
NC controller,coolanttank, and so on. Sucha processmakesfor slicksimulation,
but the only crucialpart that needsto exactlyresemblethe real machineis the
area nearthe workingenvelope.Thesemotionsmust exactlyreplicatethe real
machine.The remainderof this chapterwill coverthe processinvolvedto virtually
buildall the major machinesthat were coveredin Chapter2. The stepsare very
similar,regardlessof the simulationsoftwarebeingused.
The Skeleton
The secondbranchis also attachedto the BASE' starting with the y-linear axis
component.Observethat Y is at the same indentationas Z. The y-axis is carrying
the x-linear axis component.X is carryingthe A-rotary axis component,which
in turn is carryingthe STOCK,or workpiece.This kinematiccomponenttree is
the most basicdescriptionof a machine,and is a stripped-downskeletonof the
machine.There are no modelsattachedto this skeleton,but you can tell by a
glancewhich bonesare connectedtogether.
Components vs Models
MachineSimulation 107
different propertiesto be assignedto each of the models.Uniquetolerancevalues,
colors,translucency,visibility,and reflectivitycan be assignedto each model,
and individualmodelscan also be includedor excludedon the collision-detection
settings.
.' BASE
>B
a srocK
3x
$ rool
Figure 7-3 Vertical 3-axis machine, converted to s-axis with a third-party dual
rotary device.
MachineSimulation 109
ar BASE
3V
>A
>c
ItsrocK
€x
az
$rooL
Figure 7-4 Verticat s-axis machine with a dual, rotary, nutating table'
Figure 7-S Vertical s-axis machine with a trunnion-type dual rotary table.
MachineSimulation'l'l'l
.' BASE
*Y
3x
az
$rool
>B
>c
a srocK
Figure 7-6 Vertical s-axis machine with a dedicateddual rotary table.
'l'12
Secretsof s-AxisMachinino
.' BASE
OX
az
>A
$rrool
€Y
>c
asrocK
lvlachineSimulation113
.' BASE
€x
eY
ez
>B
$rool
Da
o srocK
Simulation 115
Machine
'BASE
3x
az
$rool
3Y
a sroc
Figure 7-7O Vertical s-axis laser machine, with a dual rotary head.
't17
l\ilachine
Simulation
SelectingThe Right Machine
For Your Application
Makinga multiaxisequipmentchoicedecisionis similarto choosinga car make
and model.The decisionneedsto be basedon the intendeduse, budget,and
personality,
alongwith many other considerations. The multiaxis\\garage"includes
the equivalentsof racecars,all-terrainvehicles,buses,and luxuryvehicles.There
are general-purpose machinesand there are machinesmadefor specificapplications.
This chapter may help narrow the searchbasedon the specificparts being
manufactured.
119
tr Selecta machinemanufacturerthat suitsthe applications criteria,and then take a
good look at the variety of pafts currently being manufacturedin your plant. Also
considerthe partsyou intendto manufacturein the future.Considerthe following
scenarios.
Are your existing CNC machines waiting for programs, or are your CNC
programmers waiting for a free machine?
If existingequipmentsits idle waiting for programs,then the workflow,CAD/
CAMsystem capability,and programmers'andoperators'proficienciesneed to be
scrutinized.If programmersare waitingfor free machines,it is againa good idea
to checkthe CAD/CAMsystem'scapability.Couldthe cutting strategy be improved?
Are the right tools beingused?Imaginerunningold style high-speedsteeltools on
a modernCNCmachinecapableof 40,000 RPMand 1500 IPM - the limitationsof
cheaptoolingcouldhold backa very capableand very expensivemachine.In the
same way, if your CAD/CAMsystem is obsolete,you won't be able to use your CNC
equipmentto its full potential.
Are you happy with the performance of your CAD/CAM system, and are you
using it to its full potential?
Makesure that your CNCprogrammers are up-to-datewith their trainingon your
CAD/CAMsystem to ensure it is being used to its full potential.It is much cheaper
and easierto get organized,trained, becomeefficient,and promote teamwork, than
it is to buy a brandnew machineand put it into production.
120 Secrets
of s-AxisMachining
New Possibilities
After determiningthat your shop is runningfull out and needsadditional
equipment,it is time to considernew possibilities. The first obvious
consideration is the physicalsizeof the machine,and that is dictatedsimply
by the sizeof the partsthat will be machinedand the sizeof your shopfloor.
The next consideration is the materialthat will be used,whichwiil determine
the rigidityneeded.The qualityrequirements of the machinewill be affected
by the expectedtolerancesyou want to hold, and budgetaryrestraintsmust
also be kept in mind. Asidefrom theseproperties,keepin mind that some
multiaxisequipment is better suited for certain types of work than others,
Secretsof s-AxisMachining
Figure 8-4 Dedicated extrusion milling machine.
Head/Table Machines
Head/Table configurations suchas thoseshownin Figures8-9, 8-10' and 8-11' are
urnon6tn" most virsatile choicesfor a variety of other multiaxisapplications.This
""rr"t]f ii'l"ri"es from the fact that the steady rest can easily be removedand the
spa."canbeusedformountingadditiona|fiXtures.CustomizedfiXturescana|sobe
built to suit specialjobs.
Figure 8-77 Machining an auger feed spira! for an injection molding machine'
Figure 8-74 This Head/Table machine is available in both vertical and horizontal
configurations,
't28
Secretsof s-AxisMachining
Figures 8-75 and 8-76 Head/Table aerospacetand Head/Table automotive
applications.
Figures 8-79 and 8-2O Typical medical part, and heavy equipment component
manufacturing.
Figure 8-22 Multiaxis machining allows for the use of shorter, tapered cutters,
Figures 8-25 and 8-25 Machiningan aerospace bracket, and a fixture component.
Figures 8-27 and 8-28 Machining rotor blades, and machining a medical
comDonent.
It is importantto make sure that the selectedsystem can handlenot only all the
differenttypes of work the shop does now, but will also be capableof taking on
futurechallenges.
Systemswith heavy CAD emphasishave their roots in CAD and are better at solid
modelingso that they can handle large assemblieswith ease.Thesesystems have
associativitybetweenall the componentsso that when a changeis made to one
feature on one part in an assembly,it will propagatethroughoutthe entire assembly.
Thesesystemsare very good at managingCAD data, but their CAMcapabilitymay
have been added later and it often does not have the same deDth.
't37
automatedcuttingstrategies. A toolpathis soongenerated,posted,and ready-
to-go.The trade-offfor this speedand easeis realizedwhen engineeringchanges
are necessary,Those changesneed to be made on a separateCAD system and
imported back into the CAMsoftware.Also, these specializedCAIYsystemswill
not suppoftany other kind of CNCmachines(lathe,EDM,plasma,waterjet,etc,)
and many won't even supportsimplecontour,drill, or pocketroutines.Thistype
of specialpurposeCAMsoftwareonly makessensefor shopsthat are machining
largemold cavitiesday in and day out. It may be necessaryto purchasea separate
programmingseat of CAD,and maybeeven anotherseat of generalpurposeCAl4.
Very few CAD/CAMsystems can do everythingwell. They all have their strengths
and weaknesses. On the other hand,very few companiesneedall the power
affordedto them by a modern CAD/CAMsoftwaresystem.The trick is findinq the
right balance.
Multiaxis CAD/CAMConsiderations
Multiaxismanufacturingrequiressoftwarethat is very strong in CAlv.CAD
capabllityis needed,but mostlyto import CADfilesfrom all the major CAD
systems,in all the popularCADdata formats.On top of that requirement,
additionalCADcapabilityis neededto createsuppoftinggeometryfor tool axis
control,fixturedesign,or virtualmachinebuilding.
consider mold and die work as an example.This work is one of the most
demandingand accuratefields in manufacturing.Moldscannot be mass-produced
but are made one or two at a time, and they have predictablefeatures,either a
core, or a cavity,or a little of both. A good 3-axis roughingstrategy will always
work well here. Some CAMsystemscan quickly and automaticallyanalyzethe
featuresand then automaticallygeneratea toolpath to machinethem' In this
shotgun approach,a wide field of targets can be coveredwith one shot.
Figure 9-3 Tool tip compensated to follow the outer surfaces of the work.
Figure 9-6 Properly configured virtual s-axis machines emulate the movements of
real machines,
Post Processor
A good post processor is the most important part of any multiaxis
CAD/CAM software. Without post processing,parts can be cut only in the
virtual world and not on real machines.The role of anv CAMsoftwareis to
generatecode that will drive the movementsof the axes on a CNCmachineso
that a part can be machined,The native CAMlanguagemust be translatedto
matchwith eachmachinet specificlanguage.Customized multiaxispostsare
usuallyan extra charge,It is importantto find out if they are availablefor each
specificmachineand how much they will cost. A professionalpost processoris
usuallydeliveredwith supportingdocumentationthat explainsits featuresand
all the availableswitchesto activatethem. CAMsoftwaretypicallycomes with
a set of genericpost processors,which are user-configurable. Ask if post-
developmenttrainingis available.
Conversations with peersor with companieswith whom the shopwill work are
usefulto learn what kind of softwarethey are using and why. Ask peopleif they
are happywith the localsupport,and was the softwareeasyor hardto learn?Can
filesfrom outsidesourcesbe importedand exportedeasily?Werethere any hidden
costs?Is the local resellerreDutable?Wouldthev recommendthe softwarethev are
using?
Choosinga CAD/CAMSystemForYourApplication
Putting It AII Together
QUrZ
1.) Name three benefits to using multiaxis machining techniques,
1.
149
3,) which of the following is the standard axis convention?
A B
1.
')
3.
5.) what are the three major building blocks of a cNc machine? (Circlethree.)
. Machinetable servo drive system . CNCcontrollercapabilities
. SpindleRPMand horsepower . CNCdrive system
. Physicalpropeftiesof the machine . Lineartable limit switches
. Chipconveyorunit
7.) What tools are needed to find the Machine Rotary Zero Position (MRZP)?
(Circle two.)
. level
. edgefinder
. dial indicator
. maintenance
manual
. hammer
't5t
Puttinglt All Together
ANSWERS
1,) Why use multiaxis machining techniques?
. Multiaxismachiningtechniquesare usedto manufacture partsmoreefficiently
and accurately
by eliminatingextraset-upsand fixturing.
. Standardshortertoolingcan be used,whichresultsin the abilityto rough
moreaggressively,whileincreasingtool life.
. A moreprecisesurfacefinishcan be achievedby avoidingcontactwith the
non-spinning
deadcenterof the tool.
't52
Secretsof +Axis Machining
Figure 7O-7 Multiaxis machining manufacturesparts more efficiently, increases
tool life, and producesa more precise surface finish,
TABLE/TABLE
HEAD/TABLE
HEAD/HEAD
5.) What are the three major building blocks of a CNC machine?
Figure to-t7 In this examplethe spindleheadand the quill move in the same
direction,but are controlledby two separatecommands,z and W respectively.
Secretsof s-AxisMachining
12,) What are the three common simultaneous multiaxis CAM toolpath
controls?
3. Tool Tip Control - Controlsthe geometryto which the tool tip is compensat-
eo.
=
TANCE
PIVOT
COMPOFFSET
LENGTH'
Figure 7O-75 Step 1: Level the A-axis. Figure 1O-16 Step2: Findx,Y center.
Figure 70-79 Step5: log Z minus the radiusofthe rotary table diameter,and
adjust gage tower height to match.
PuttingltAllTogether 163
Finding the Pivot Distance
For Head/Table and Head/Head Machines:
Z max
Z min
GL - Gage Length
R - Dowel pin radius = .5OOO
Formula to calculate Pivot Distance:
PD=Zmax-Zmin-GL+R
ltAllTogether 165
Putting
Indexing/Rotary Positioning Work Overview
Also known as 3+2 machining,indexing/rotarypositioningwork, illustratedin
Figure 10-24, is the most basicmultiaxisconcept.The rotary/pivotingaxes are
used only for positioning,and the cutting takes placewith only the three linear
axes moving.Indexingwork is rigidand precise,It is recommended that all
possibleroughingoperationsbe performedin this rigid state.
'166
Secretsof s-AxisMachining
Machine Simulation
Do not assumethat machinesimulationis usedonly for prove-outswith the sole
aim of findingerrorsin the code.Instead,machinesimulationshouldbe regarded
as an additionaltool to help make clean,efficient,and accurateprogramsevery
time. Machinesimulationpermitstesting of differentapproaches,differentcutting
strategieson different machines,without leavingthe desk. There is also no need to
tie down a machinefor VourDrove-outs.
In Conclusion
Desiredcutterarea.engaging,l0
dcfined,l4 Dovetail effecl. 98
substitution,32 Dynanic
contol of tool axis,90,98
B robry fixtureoffset.16.27-8,36
Bal]-nosecutters,10,96,130
Bettersurfacelinishes.l0 E
Effectivcwork envelope.16
(- Engagingdesiredcutterarea,l0
CAD/CAMsystems, 3,7. 27, Extrusionmillingmachine.123
capabilities.l39
multiaxiscoDsiderations,
I 39 F
origin,60 Fanucprogritn,34
selecting,137 Fcedrate,T2
softwaredevelopmcnt, 145 dynanicchanges. 138
rcsearching,146 inversetime,74 6
tmining,l4,l optimizaiion,l3S
Calculating pivotdisiance(PD),33,37-8,169 standardlime. 74
CAM, multiaxis,139 Findingthe
Can-operated multiaxismachines,3 ccnterofrotation.21.27'8
Changeable spindleheads, 53 pivotdistance,33,36-9.l6l. l6,l
Checkingpositioning repeatibjlity.'12 XYzero,23
Circular 5'axis
73
interpolation, nachineierms,13
vectorInres,76,159
Cleancore,92
CNC nachines,39
controllers. 3, 76 positioning,T
capabilities,l3,157
drivesystems, l3
Collisionavoidance (seeAvoidingcollisioDs) G
Common misconccptions, 4, 6. 7 Gage
Complexity of rvork, 120 length(GL),36-9. 161
Computernunericalcontrol,3, 92 tower,24,163
Crashirg,I I 7 Ganrrytypehead/head 122,134
machines,
Cutpattem,79,86 94, 140,161 G codes,29.30.56, 104'106
169
sinulntion.105 M
G 90code.29.30 Machine
G-91code.29.30 aclivccoordirrte
system.257.57 61.140,15'
Gaphicaluscrnrtel1ace,
ll6 1136,116-7,139.1,13
bxildingvirtual,64, 4, 167
busnrcsscnd,6,l,107.125
H coordinatesystems,257,56-7.61'2.1,10.
159
Head/head 18.367. ll5 6.
nrultiaxismachines. homeposidon, 16,57.60.78. 157
l2l 2. 13,t.156,i64 slstcns,25,26. 6l
localcoordinate
bridgeiype. 122
ganlry1ype,122.13,1
lasercuttingmichnre,116.135 hone positior(MRHP),l7
warcrjer miling machnre.ll6. 134 zeropoint,21,25-7,36.60 2,1 1 2, 1M
18,31.36.113,1
Headltablenrultiaxisnrachnrcs, zeroposition (MRZP).I 6 '7,21,25.21.36,
123,1.155 1 1 7 , 1 5 8 ,r96.2
aerospace, automotive 129,133
applications, simulrtion,27,63-4,98. 1036. 143.1657
millingenginchcadports,125 graphicaluserinlefaccs.I l6
nilling longrotarypafts.124 using.tl7
mdd anddic applications, 130 Machirlnlg
nuiatingheadconbinations,129 centcrconJigul"tion. 108 I l0
rotafylxble,rilthg head.12830 complexworRpicccs,5
variousconligurations,1249 cngnrccomponents.20
with longX'axis tavel. 123 profiling. ll5
Ho\vCNCmachines work,56 progrrn,29
Historyof 5 axismachining.3 routines.5. 104.138
spnd bevelgears.68
Machsimsoftwxlc,106
I
Maintenance issues.40
I n d e x n r g , 2 l , 4 4 , 5 11
, 5353.
Manualclrt.tinpur(MDl),25.1l6
lixtures,5l
Master
methods.5l
coordinalc system,60
toolpaths.49
zero,26
wirh rotar)devices.52
M-code.2l,43,60
wo*.:19.55
Milling nachineswith nvc or moreaxes.4:l
Indusrrial robots.135
\ 4 o , r e l i n2-r. ., ' 1 . u l . l l ' . I n - P l l 6 l 1 - - r )
Interpolation
159
circular,T3
Multiaxis machines.3 6. 8, 17-9,40,7,1. 124.153
linear,73
camtype.3. 140
Inversetnncleedrate, 72-4.76
dedicated,6. 9 10.21.39,52-3,110,l2l)
designilions anddirections.l5
L physicalpropeties,13.156
rorghing. 21.101.130,1402, 166
Leadandlag jn milling.100 Multiplenestnrg, 58. 61
Lnnihlions,,16
Linear
106.121,166
.txis,14 6,34.,19.74,
N
NeslingpositioDs.
25.26,56 8, 61
73
interpolation.
Newpossibilities,
11.121
Localcoordinate systems.257.56 8.61 2,117
Nunbersof parts,
120
170 Secrets
of s-Axlsl\,4achining
Nunerical conlrol. 3 R
Rcpcating pxltcrns,l0,l
o Rotary
Old schoolsimulatifl. 104 andpivotingaxcs,32.74
One zero meihod,60 axis,16,21,33.,12.60.71.7.1, 107.i21, 156
Optimum rvork envelope.70 d c v i c c1
s ,6 , 1 8 . 2 1 . 521, l l 6 . 1 5 5
Odgin,26,60 xrdexingnechanisns,5, 54
mcchanisns. 6, 19,20.39.403. 52 3. 7l
P tool cortrolpoint(RTCP).33'4.36.l6l
Palletchargers,
40, 54, 107-8
Rotarytables,5.
8.9. 18,21,278.31 2. 130-2.
datum,17,21.27,58,158 r 5 56 .r 6 3
zeropoirt (PZP),27 8 brakes,21,.10, 52.l0,l
Plungeroughing,101-2,142 d e v i c e1s 6. ,1 89 , 2 1 , 5 12 . 7 7 .1 0 9 1. 1 6 ,1 2 61. 5 5
dynxnicfixlurcoft.\cl(RTDFO).16,27 8.36
Probesandprobing,94-5,103',1 sinsleanddual. 6, 8. 18.39.ll9
Roughnrg. 11,21,101'2,130,140'2,152,166
I'hysicalproperties
of5-axismachines, 13 Routnrcs,5.40,42, 1045
Pivot
distance.33 S
point,379 Secondrotart table,18
Pivonngspindleheads,18,32-6,38. 124.156.lbo Selecfirgnachnlcs,I l9
Pockct nrilling.5.86,l2l, ll7 9 Selectingsoftware.137
Positioning$ork. 5, 7, 8. 13,20-l, 26. 42,49,52, Stullrlaftrn,
19,27,47.63 4.98.10317.I38,1667
r 5 9r,6 6
cutlingmotions,10,71
processing,3.4.8.34,40,76 8. 103-6,138, millingte.hniques.2l
1 4 37 , 1 5 9 r, 6 6 muhiaxistoolpathconirols,79,101,152.161
processor,3,4, 8,39,40,769. 10zl6, I16,138. toolpaths. 5.48.65.78. 103,105,107.l2l
1 4 3 1, 4 7 , 1 5 9 Special-puryosesoftlvare,137
Probingroutines.1045 Spindle heads.changeable. 31.53
Program Spil"l splines,99
nnnurleditnrg. 104
subloutines. 9, ,13-4. 10.1 Standard multiaxisnomenclature.
15
zcroposition (PZP).l6 8,25.32.117.158-9.162 Slock(natcrial)option1.47.102
-
P r o g r d m n r i l gq...118 . 2 4/ 5
. 6 .5 4 . 6 ) . l . l 0 : . rccognition,1,12
105.138,144.147 Subroutines.3.43. 104
.onsiderations, 46 Surlacelinishes.better,5,10
languages,3
limitrtions.46 origin.60
view,27
a
Qucstbnsandanswers, 46. I 44. I 41. 119 T
physicalpositions,151,157 Txblc/lxblc multiaxis machnrcs,
l8 9.24.I10.125,
standard
axisconvention. 150.154 1 3 2 1, 5 5 . 1 6 2
wjth port-nillingaftachment, 125
'171
honnionandrock andro11Iixtules,71. 111,I32
variousapplications. 133
3D surfacing toolpaths, 5
Tiltingspindleheads,31
Tombstone lixtures,6, 40, 58-9,108
Tool
axiscontrol,79,86,89,91-2,98, 139,l4l, 161,
lengrhoffsets,18, 24, I 17
lists,46,140,145
for lathes.138
simultaneous,65
planewith odgin,27
tip control,79,90-91,l4l
Tradeshows,146
Training,144
2 + 3 positioning,49
U
UsingmotionsXYZ andC,67
Unlockedrotary drives, 11
U\r!V linear axes,15
v
Vericutsoftware,1,95, 106,116-117
Verilication system,27, 104
Visitingsoftwarecompanies, 1, 146-7
Virtualmachine,103,105
building,l06
components andmodels,107
configudngfor simulation,105
kinematiccomponenttlee, 107
skeleton,106
w
wire franes,79,103,139-40
Worldzero,26,60
x
7,74
XYZ linearaxes,15.32,66
z
Zeroingthe indicator,22
Zeroposition, 17,21,117.158,162
Z-Maximum,37
Z-Minimum,38
Installation
The enclosedCD should run automaticallywhen inserted into a CD-ROlqdrive. if the auto-
run feature does not work. please use File I\4anagerto navigateto the CD. Find the file called
Index.htmland dolrble-click it.
System Requirements
The CD was built to run ootimallvon a PCwith:
. WindowsXP or Vista
. Internet Explorer(Version7) or higher
. 1024x 768 resolution(or higher)
. Adobe@ Acrobat Reader@ installed. (Go to http://www.adobe.com/downloads/to install a
free version,)
. AppleQuickTimeplug-ininstalled.(Go to hftp://www.apple.com/quicktime to installa
free version,)
. If you installthis cD on your hard disk.you will need650 l4Bfree space.
. Real Machining videos - watch a real s-axis machine pefform several different
multiaxiscuttingroutineson complexsimulLaneous 5-axisparts,
. Printable PDF Files - Quick Referenceguidesfor the most important aspectsof setting
up a s-axismachineand commonmultiaxisconceptsall availableas easyprint-outs,
Technical Questions:
Pleaseemailyour questionsto info@industrialpress,com
or to the authorat
Or visit www.5axissecrets.wordpress.com
karlo.apro@gmail.com. and go to the link for FAQS.