ABC 5X-Milling

hyperMILL® V7.
The ABC of
5X Simultaneous Milling
Basic Technical Principles

Contents
Contents
1 Why use hyperMILL® V7 for 5X milling? ............................................................................. 3
The advantages over 3-axis milling ...................................................................................... 3
2 Machine Axes and Kinematics ............................................................................................. 5
The machine axes ................................................................................................................. 5
Linear axes ....................................................................................................................... 5
Rotary axes ...................................................................................................................... 5
Additional axes ................................................................................................................. 7
Different machine kinematics ................................................................................................ 7
Head-head kinematics ...................................................................................................... 7
Table-table kinematics ..................................................................................................... 9
Head-table kinematics .................................................................................................... 10
3 Machine Axes Milling Path and Movement ....................................................................... 12
Definitions ........................................................................................................................... 12
Machine axis movement profile .......................................................................................... 12
3-axis milling ................................................................................................................... 12
5X Simultaneous milling ................................................................................................. 12
4 RTCP (TRAORI, TCPM, PTLC) ............................................................................................ 13
The abbreviations ........................................................................................................... 13
Mode of operation ............................................................................................................... 14
Positioning ...................................................................................................................... 14
Calculation of the feedrate ............................................................................................. 14
The meaning for 5X simultaneous programming ........................................................... 14
RTCP as controller function ................................................................................................ 15
RTCP tests ..................................................................................................................... 15
RTCP as a function of the postprocessor ........................................................................... 18
5 Programming the Rotary Axes ........................................................................................... 19
Default specified value for the rotary axes .......................................................................... 19
Incremental angle values .................................................................................................... 19
Apparently infinite rotary axes ........................................................................................ 19
Angle value between 0° and 359.999° ................................................................................ 20
„Actual‟ infinite C-axis ..................................................................................................... 20
Test for the infinite C-axis ............................................................................................... 20
6 Machine and Controller Test .............................................................................................. 22
Strip test .............................................................................................................................. 22
Dynamics test...................................................................................................................... 23
Interpretation .................................................................................................................. 23
Proof test ............................................................................................................................. 24
7 Workpiece Clamping Position ............................................................................................ 25
Singularities ......................................................................................................................... 25
Avoiding singularities .......................................................................................................... 27
hyperMILL® V7 2 5X Simultaneous Milling

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1 Why use hyperMILL® V7 for 5X milling? Us
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The advantages over 3-axis milling
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Compared to standard 3-axis milling cycles, 5-axis (5X) milling cycles offer considerable advantages when it
comes to machining cavity and dome geometries with steep walls: H
Tool lengths are shortened (producing a more favourable length/diameter ratio) o
 More rigid tools
 Lower tool costs
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 Tool life is increased thanks to lower vibrations and by avoiding central cutting
(no chipped edges with solid carbide tools)
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Achieves improved process parameters
 Higher feedrates thanks to shorter tools b
 Reduced cutting forces
 Tools less prone to chatter
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 Lower risk of tool breakage
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Less milling fixtures required pl
 Savings potential for machine running times and fixture costs
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Fewer individual jobs required because there is no need for manual indexing when creating jobs
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 Clearer job lists, fewer frames e
No surface offsets between the indexing areas te
 Less manual rework-machining on the workpiece
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Us No special tools required
e  Fewer tools
Reduction in tool costs
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to Automatic collision avoidance that goes well beyond the normal collision check
 Entire programming in just a few steps
ap  Tool and holder collision check
pl Definition of the preferred angle to the Z-axis and orientation of the tool axis to a freely-definable
y and/or automatically calculated guide curve
 Predictable tool and machine movements are easy to generate
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2 Machine Axes and Kinematics Us
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The machine axes
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Linear axes e
To remember the positive alignment of the linear axes, raise your right hand and „allocate‟ your thumb as the
X-axis, your index finger as the Y-axis and your middle finger as the Z-axis. H
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Rotary axes
For multiple-axis machines, the rotary axes are added to the linear axes (X, Y, Z). These are generally
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termed A, B and C.
The A, B and C-axes are allocated to the linear axes:
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We will not go any further into special kinematics here.
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Us Allocation of the rotary axes to the linear axes
It is easy to remember the allocation of the rotary axes in the following way:
e  You normally list the axes in alphabetical order: Let‟s say “X, Y, Z”.
th You can now list the rotary axes, A, B, C, in the same order as you listed the linear axes. If you list the
linear and rotary axes opposite each other in the same alphabetical order you will get the following pairs:
e X–A
H Y–B
Z–C
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ta Direction of rotation of the rotary axes
To establish the direction of rotation for the rotary axes, imagine the following:
b  Point the outstretched thumb on your right hand upwards (all other fingers are also outstretched). If you
slowly make your other fingers into a fist, then these fingers will so to speak „rotate‟ about your thumb,
to which is pointing upwards. This „rotation‟ corresponds to the direction in which the rotary axes move in a
positive direction:
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Additional axes Us
The same is true for the additional axes (vector axes) as for the rotary axes:
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 Allocation to the linear axes is also made in alphabetical order. The positive direction for the U, V and W-
axes corresponds to the positive direction of the linear axes. th
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Source: Heidenhain ap
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Different machine kinematics
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Head-head kinematics
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A and C-axes in the head (fork head)
Manufacturers/machines: Breton, Droop+Rein, Fidia, Mecof, Rambaudi and Zimmermann rs
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Us A and C-axes in the head (Z-axis offset from the tool axis)
e Manufacturers/machines: Depomat
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to Nutated B and C-axes in the head
Manufacturers/machines: Anajac, Mecof, Soraluce
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Table-table kinematics Us
A and C-axes in the table (rocker arm) e
Manufacturers/machines: Alzmetall, Hermle, Makino and Mazak
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B and C-axes in the table (rocker)
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Manufacturers/machines: Bautz
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Nutated B and C-axis table 1
Manufacturers/machines: A/C Huron, B/C DMU eVo
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Us B and C-axes in the table
Manufacturers/machines: Micron HSM400, Realmeca
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Head-table kinematics
ap B-axis in head, C-axis as rotary table
pl Manufacturers/machines: DMU T series, AXA VHC
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Nutated B-axis in head, C-axis as rotary table Us
Manufacturers/machines: DMU P series, DMC U series
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A-axis in head, C-axis as rotary table
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Manufacturers/machines: Huber + Grimme ap
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Us3 Milling Path and Movement of Machine Axes
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Definitions
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e Tool reference point:
The tool length is given relative to a reference point. This point lies:
H  On the tool tip for end mill cutters
o  On the tool tip (tip) or level with the centre point (centre) depending on the tool measurement for bullnose
endmills and ball mills respectively
m Milling path = reference point path

e Pivot point = rotary axes intersection
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Machine axis movement profile
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3X Milling
ap For 3X milling, the (X, Y, Z) linear axes movement profile corresponds to the reference point path profile for
pl the tool relative to the machining zero point.
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5X Simultaneous milling
Ü For 5X Simultaneous milling, the profiles for the path described by the machine axes (pivot point path) and
be the reference point path are different:
rs Programmed path of tool Path of machine
axes
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The reason for this is simplified in the following diagram: Us
In this example, the machine has to perform a compensatory movement in the X and Z-direction to maintain
the reference point when the tool is tilted. e
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Source: Heidenhain
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For all the rotary movements, compensation movements can occur on all three linear axes depending on the
kinematics. According to the machine kinematics, the resulting movement of the machine axis compared ap to
the 3D path can become simpler or more complicated.
pl
To keep the tool reference point on the required position, the linear axes offset must be calculated and
compensated in the controller using adjusted path specifications.
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RTCP functionality is used for this.
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4 RTCP (TRAORI, TCPM, PTLC) rs
The abbreviations ch
All the abbreviations essentially mean the same thing. However, every CNC controller manufacturer likesriftto
use his or her own terms for the developments they have made in this area.
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RTCP = Rotation Tool Centre Point
TRAORI = Transformation Orientation to
TCPM
PTLC
= Tool Centre Point Management
= Pivot Tool Length Control
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We will use RTCP in the following.
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Us of operation
Mode
e The RTCP transfers the conversion of the reference point path into the corresponding machine axes
th movement, taking into consideration:
 The current clamping status
e  The machine kinematics and
H  The tool length
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Positioning
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The RTCP creates a compensation movement for the relevant linear axes if one of the rotary axes will
e move. It does this in such a way that the position of the tool reference point (centre point or tip) always
remains constant.
ta If the position of a controlled rotary axis is changed in the programme, then the position of the tool tip
b compared to the workpiece remains unchanged during the tilting process.
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Calculation of the feedrate
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pl The feedrate in the tool reference point is decisive for milling.
y The RTCP calculates the feedrate effective on the machine axes so that the programmed feedrate in the
tool reference point is maintained.
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If the machine cannot achieve the intended target position window (due to inertia, torsion in the driving
be spindles etc.), then the feedrate will be additionally regulated downwards until this occurs without difficulty.
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The meaning for 5X Simultaneous programming
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rift The following should be observed when creating a 5X job: to minimise the scope of the calculations required,
the planning strategy should take into account the fact that the machine axes should be kept as stable as
1 possible because this is where machines can be seriously hampered.
to As a rule: the best 5X job is a job that only has movement on three axes.
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hyperMILL provides you with a whole range of effective tools for this. More about that later….
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RTCP as controller function Us
The required postprocessor provides the tool reference point path as well as the angle of rotation
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necessary for optimising tool orientation.
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The controller makes the calculations required for 5X Simultaneous milling (position, feedrate on the axes).e
This process is continuous. The controller constantly seeks to execute the calculation of the axis correction
value while adhering to the feedrate value. The kinematics are also included in the calculation at the sameH
time.
You can no doubt image what kind of demands a simultaneous movement of all the machine axes makes o on
the controller‟s calculating capacity and Look Ahead.
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RTCP tests e
You can use the following tests to simple check whether the controller is equipped with RTCP functionalityta
and if this is working properly.
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Before you process real workpieces on your machine, it is essential that you test whether the RTCPto is
functioning correctly. If the RTCP is not working correctly or at all, this may result in serious damage to the
workpiece or machine. ap
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Mrginal conditions for both tests y
 On your machine table, clamp as long a ruler as possible parallel to the X-axis.
 Start all of the rotary axes at 0°. Ü
 Clamp a ball mill in place; the centre of the ball mill is the reference point for the tool.
 Position the machine so that the tool is located either as near as possible over or sideways from one of
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the upper edges of the ruler. rs
 Place your zero point here.
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RTCP test 1: tool length compensation
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Traversing block:
 Programme a traversing block from X0Y0Z0 A0C0 to X1000Y0Z0 A20C0, for example.
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 Observe how the machine now travels from the first to the second set of coordinates and how the axesth
behave.
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Stipulated result:
The tool reference point describes a straight line in the X-direction. This means the tool reference point
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travels along the edge of the ruler without changing the height, Z.
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See the following diagrams. th
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Us Top view:
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e If your machine behaves as shown, it will be possible to correct the tool length on the controller.
te If the machine behaves differently, you will have to purchase this functionality later or implement it via the
xt postprocessor.
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RTCP test 2: full kinematics RTCP functionality Us
Traversing block: e
 Position the machine at X0Y0Z0 A0C0 again.
 This time, programme the traversing block to X1000Y0Z0 A20C60 and move the machine on this block.
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Stipulated result:
The offset in direction X caused by the rotation of the C-axis must also be compensated alongside the toolH
length (correction in Z by rotating the A-axis).
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The tool reference point must also describe a straight line in the X-direction without changing the Y and Z
coordinates (in the Y and Z corrected path):
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See the following diagrams.
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Top view:
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Front view: rs
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Us If your machine behaves as shown, your controller has full RTCP functionality.
e If the machine behaves differently, you will have to purchase this functionality later or implement it via the
th postprocessor.
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Test with gauge
H If the first test has produced the desired results regarding the necessary axial corrections but you still have
o the impression that your machine position is not quite right, then you should check whether the individual
machine components important for RTCP are also correctly measured.
m
e  Check the starting positions on the tool tip and the bull mill with a gauge.
If you are not satisfied with these results, contact your manufacturer.
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b For your own safety, you should perform the gauge test after every collision.
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RTCP as a function of the postprocessor
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y Ifproduces
the controller does not have RTCP, it is possible to verify this function in the postprocessor. This generally
shorter NC programs.
Ü Depending on the RTCP definition, a postprocessor with RTCP functionality does not produce the actual
be milling path – the reference point path – but the pivot point path instead.
rs Here it must be ensured that the following are known prior to the postprocessor run:
ch  Workpiece clamping position
Exact tool length
rift  Tool holder and tool combination
1 If these preconditions cannot be reproduced exactly, then the postprocessor run can only be performed
to after preparing the machine and entering the corresponding values.
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5 Programming the Rotary Axes Us
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Default specified value for the rotary axes
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As a rule, controllers have different methods of interpreting the default specified values about the rotary axes.
This concerns:
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 Interpretation of the signs (+/-) as the direction of rotation
 Limitations in the rotary axes on the software side; infinite or relative to a revolution o
 Type of angle value default; absolute or incremental
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The various modes are controlled via the controller parameters and/or special controls in the NC
program.
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Please consult your manufacturer about:
 Your machine‟s settings for the controller set-up (controller parameters) b
 The effects of making changes to the parameters
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Controller set-up and the NC program must be matched using an appropriate postprocessor. ap
If the data in the controller set-up and the NC program is contradictory, then the settings in the controller set-
up apply. pl
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Incremental angle values Ü
Apparently infinite rotary axes be
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The following is valid for the incremental angle values (apparently infinite rotary axes):
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 The controller does not interpret complete revolutions.
- e.g. Heidenhain controllers: controller parameter 810.3 = 0
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 An infinite continuous angle is assigned to the circumferential rotary axes – generally the C-axis – in1 the
NC program.
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Empty rewind th
Since the controller does not interpret complete revolutions, several „empty‟ revolutions can be created when
setting the initial position of the axis starting from the current angle value.
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As a rule, this „empty rewind‟ can be avoided using controller commands.
With Heidenhain devices, using the M94 command or by additionally entering the axis will set the display and
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the memory contents respectively back to an angle of between 0° and 359.999°. xt
Please consult your controller manufacturer or possibly your supplier to establish which controller command th
does this.
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Us limitation
Angle
e Individual controllers limit the maximum permitted angle via a further controller parameter. When reaching the
defined angle value during processing (e.g. circumferential Z constant finishing), the machine may
th automatically rewind the axis! As this occurs in the current position, there is serious danger of collision!
e Ask your controller manufacturer which parameter this is. If necessary, change this to the highest permissible
value (e.g. 99999° on the Heidenhain; corresponds to approx. 277 revolutions).
H When programming, ensure that this value is not exceeded.
o Use controller commands as required to reset the axes memory contents.
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e value between 0° and 359.999°
Angle
ta infinite C-axis
‘Actual’
b
The following applies:
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ap  The controller interprets complete revolutions.
There is no max. value for the C-axis, which means the C-axis will not rewind.
pl - e.g. Heidenhain controllers: controller parameter 810.3 = 360
The result is an ‘actually’ infinitely rotating C-axis.
y  For the circumferential rotary axis – generally the C-axis – only an angle value within a full revolution (0 
Ü Angle  359.999) is allowed in the NC program.
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Pole pass: constant direction of rotation, shortest path
rs For circumferential machining, you must ensure the following using the appropriate controller parameters:
ch  Ensure
359.999
that the rotary axis maintains a direction of rotation from 359.999 to 0.00 and from 0.00 to
rift -- e.g. with the Heidenhain: controller parameter M126 or

the controller parameter that regulates the behaviour of the rotation axis when passing through the
1  Also360°/0° position
ensure that the machine hereby takes the shortest path (shorter-path traverse of rotary axes)
to when passing the 0°/360° position (pole pass).
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e for the infinite C-axis
Test
te It is essential to test the behaviour of the C-axis prior to performing 5X machining.

xt The following behaviours and examples described are based on the Heidenhain TNC 426, 430 and 530.
th Other controllers have equivalent commands and parameters.
Please consult your controller or machine manufacturer as to whether and how you can or should make
at changes to achieve infinite rotating without rewind.
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 Programme one of the following examples using hyperMILL or on the controller (using the Shortest Path
command).
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 Follow your machine‟s behaviour while the program runs. e
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Example 1:
Actual position Specified position Traverse
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350°
10°
10°
340°
+20°
–30°
H
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If your machine travels with the value listed under Traverse in Example 1, then your machine is performing ma
shortest-path traverse and therefore behaving correctly.
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Example 2:
ta
...... b
223 L X1.1991 Y99.9928 C359.313
224 L X0.3997 Y99.9992 C359.771 to
225 L X-0.3997 C0.229 (0° C-axis pole pass)
226 L X-1.1991 Y99.9928 C0.687
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227 L X-1.9983 Y99.98 C1.145 pl
228 L X-2.7975
...... y
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Your machine is behaving correctly: if it travels in 0° pass, i.e. from block 224 to 225 in the rotation movement
listed above without suddenly making a nearly 360° reverse rotation. be
If this is not the case, please consult your machine or controller manufacturer about how to resolve the fault.
rs
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Turn the machine off completely after changing the controller parameters so that the controller can rift
activate the adjusted parameters when the machine starts up.
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Us6 Machine and Controller Test
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Strip test
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e The following test describes a simple way to check the interplay between the machine, controller and your
machine‟s dynamics. This is the so-called strip test.
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Programming
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be The individual strips should be multipass milled from top to bottom using a ball mill on a steel block.
rs  Write the appropriate program on the controller.
Programme the line width to produce a scallop height of around 0.001.
ch
rift The best result would naturally be when no difference can be discerned between the individual strips. You
can draw the following conclusions from deviations between the strips:
1
Fault analysis
to Deviation
th From 1
To
2
Error
A-axis not correctly positioned; assembly error not compensated
e 3 4 C-axis not correctly positioned; assembly error not compensated
5 6 If the first half of strip 6 displays the same image as for the whole of strip 5 then there is
te an error on the gear in the A-axis
xt 7 8 If the first half of strip 8 displays the same image as for the whole of strip 7 then there is
an error on the gear in the C-axis
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Dynamics test Us
You can use this „extreme test‟ to establish your machine‟s limits.
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Programming
The individual strips should be multipass milled from top to bottom using a ball mill on a steel block. e
 Write the appropriate program on the controller.
H
 Programme the line width to produce a scallop height of around 0.001.
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Interpretation Ü
A glance at the following graphic makes it clear that extreme demands are being placed on the axis be
synchronisation. The graphic does not display actual axis acceleration, but is rather intended to clarify the
extreme demands placed on the machine. rs
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The jump in the theoretical speed and corresponding problems regarding the cycle pass and synchronisation
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of the axes grow disproportionately with the increasing X value. A certain waviness occurs on the milled
surfaces in the stationary point area. This waviness increases parallel to the acceleration.
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If vibrations at the stationary point continue over a large area, please contact your machine manufacturer
about how to optimise the axis drive. at
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Us test
Backlash
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Procedure
th The following test serves to establish how big the backlash is on your machine when it rewinds the direction
of rotation.
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We have made an e3 file with a 5X job available for this.
H Backlash_test_01.e3
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The forced effect is clearest when you actually mill this part on your machine:
rift The C and A-axis directions of rotation change twice during the program pass.
1 To understand this more clearly, see the program run with the machine simulation. The reversal of the
to direction of rotation can be clearly recognised.
th Backlash_test.avi
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Interpretation
You are familiar with the four small markings that appear on 3-axis CNC milling machines on passing the
te quadrants when milling an outer circle or circular pocket.
xt These are more or less small, depending on the quality of the machine and the controller parameters
settings.
th The same effect is produced on the rotary axes in our preceding test. At this point, the user must decide how
at much he or she is prepared to tolerate.
It must be clearly stated that your machine is not suitable for 5X Simultaneous milling if the error is still so
yo large that it is unacceptable, despite trying different settings on the machine and controller.
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7 Workpiece Clamping Position Us
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Singularities
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Definition
The term singularities refers to ambiguous axis positions.
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H
Singularities often affect the C-axis.
 The positions 0° and 360° are not identical for 5X machines with an infinite and unblocked C-axis. o
 Using the fork head, the positions C0A20 and C180A-20 produce the same position for the tool relative to
the part.
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Behaviour when approaching singularities
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ta
Travel should occur from the start position C0 A-40 to the finish position C0 A40 (= C180 A-40) in the
following: b
Start position C0 A-40
Side view Top view
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Finish position: C0 A40 (= C180 A-40)
Side view Top view
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Us Positional behaviour for C0 A-40  C0 A40
e Traverse path 1: C0 A-40  C0 A40 (correct) Traverse path 2: C0 A-40  C180 A-40 (incorrect)
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H
o
m
e
ta
b
to The head moves from C0 A-40 to C0 A0 and
further to C0 A40. This means that the A-axis
The head remains at C0A-40 and only moves on the
C-axis, and then about C180, without the A-axis
ap pivots through 80° without the C-axis moving. being moved.
This movement corresponds to the shortest path This does not correspond to the intended
pl as well as the intended movement. movement.
When milling and swarf cutting, this is likely to
y produce processing errors.
This rotation about the C-axis is not a programmed
Ü rotation and is therefore not checked for
collision.
be In such cases, the postprocessor must ensure that
rs the shortest path is observed and pivots through the

A-axis.
ch
rift Explanation of position behaviour 2:
1 Please look at the following two diagrams to clarify what the machine is doing at this point.
to
th Pole pass
e
te
xt
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at
yo
u
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an V7
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ror
!
The machine travels from N001 to N002 and therefore passes the pole. The machine uses the pole passUs to
make a rotation about 180° on its way from N001 to N002. This happens constantly on the path between the
two points. The path, described by Point 1 (P1) on the milling tools, cuts through the part to be milled and e
therefore damages the component („collision‟).
th
e
If this behaviour occurs, then it is essential to avoid pole passes and singularity positions during
programming. H
To make this easier to understand, we have included some videos that clearly show the undesired behaviour.
o
The videos show two identical machines with identical controllers. Only the software versions on the
controllers were different!
m
e
Pole run correct.avi Pole run incorrect.avi ta
b
Avoiding singularities to
To avoid any embarrassment regarding singularities that might occur, we strongly recommend that you check ap
the appropriate component for existing singularities. Then bring the component onto the machine using a
device in a (tilted) clamping position, which does not allow any pole passes to be expected. pl
 This is simple to check: place silhouette lines over the surface to be milled using the
feature.
Contour y
 Do this from the X and Y-direction. Ü
Pole passes are to be expected where the lines cross.
 By tilting the component (or workplane) and creating the silhouette lines again, you can see whether the be
tilt performed is sufficient to avoid pole passes.
rs
See the following diagrams.
Component with a slightly curved upper surface:
ch
rift
1
to
th
e
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xt
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u
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® V7
t
ror
!
Us Silhouette lines for various pivotings about the X-axis:
e
th
e
H
o
m
e
ta
b
to
ap
pl On the intersections between the silhouette lines, you can see that the silhouette lines migrate towards the
edge of the component as the tool pivoting increases.
y If the silhouette line is on the edge, you can assume that no pole pass should occur.
Ü However, the leading angle must also be taken into account. After all, this method enables you to make a
good and proper assessment of the component with respect to pole passes.
be
rs Singularities_03.e3
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rift
1
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u
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an V7

ABC 5X-Milling

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ABC 5X-Milling

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hyperMILL® V7.

Basic Technical Principles

hyperMILL® V7 2 5X Simultaneous Milling

m Milling path = reference point path

rift -- e.g. with the Heidenhain: controller parameter M126 or

te It is essential to test the behaviour of the C-axis prior to performing 5X machining.

rs the shortest path is observed and pivots through the

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