Secrets of 5-Axis Machining

Karlo Apro
7 ISBN978-0-8311-3375
ttn ril llillffill
Secrets
ot S-Axis
Machining
by KarloApro
Industrial Press, Inc. NewYork
Libraryof Congress Cataloging-in-Publication Data Apro, Karlo. Secretsof s-Axis lvlachining Karlo Apro. / p. cm. Includes index. rsBN 978-0-8311-3375-7 1. l4achine tools--Numerical control.2. Machining.I. Title. IL Title: Secrets 5-AxisMachining. of TJ11B9.A68 20OB 671.3'5--dc22 2004027254
IndustrialPress, Inc. 989 Avenueof the Americas New York,NY 10018 FirstPrinting, August,2008 Sponsoring Editor: lohn Carleo lnteriorText and CoverDesign: Paula Apro Developmental Editor: RobertE. Green Production I\4anagen lanet Romano
Copyright O 2009 by Industrial PressInc., New York. All rights reserved.This book, or any parts thereot may not be reproduced,stored in a retrieval system, or transmitted in any form without the permissionof the publisher. All trademarks and registeredtrademarks, including Mastercam@ Vericuto, are and property of their respectiveowners. All rights reserved. STATEMENTOF NON-LIABILITY No liabilityis assumedby the author or publisher with 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 pubiisher assumeno responsibility errorsor omissions. for Publicationof any data in this book does not constitute a recommendationor endorsement the authoror publisher any patent,proprietary by of right, or product,
10 9
Printed Thomson by Press IndiaLimited
Dedication
Thisbookis dedicated, loving in memory/ my motherPiroska. taughtme to She the meaning hardworkandperseverance. of Although passed she awaybefore the completion this book,her spiritcontinues livewith me. of to
Acknowledgements
I wouldlike to thank Yavuzlvlurtezaoglu giving me the inspiration write this for to
DOOK.
A special thanksto LauraNortonfor her humblinginsights. And aboveall, I would like to thank Paula Apro, my hard-working wife, friend,editot For designer, and manager. without her this book would neverhave come to be.
All the imagesin this book, including the virtual machines, were modeledusing (CNCSoftware, f4astercamo Inc.). The virtual machines were broughtto life using (l"loduleworks) VERICUT6 the machine simulation capabilities 14achSim of and (CGTech). pleasecontactl Formore information these products companies on or Machsim/Moduleworks CGTech/VERICUT CNC Software/Mastercam Moduleworks GmbH 9000 ResearchDrive 671 Old Post Road Ritterstr,12 a Irvine, California 92618 Tolland,CT 06084 52072Aachen,Germany 949.753.1050 860.875.5006 +49.241.4006020 www.cgtech.com www.mastercam.com
www.moduleworks.com
Formore information the author,Dlease on visit www.multiaxissolutions.com
Table of Contents
Introduction ... ....., . . .1
C h a p t e 1 : H i s t o r y o fs - A x i s M a c h i n e.s . . . . . . 3 r .
C o m m ol n i s c o n c e p . . o.n s 4 ti. , R e a s o n o l J s e u l t i a x li \ 4 a c h i n e s . ts M s .... .......4 ,,,....,B
Chapter2! nowYourMachine......,,,.,..13 K l4ultiaxisl\4achineConfigurations .........74 T a b l e / T a b l e M u l t i a x i s l 4 i c lh nn e s . . . . . . . . . . . . . . 1 8 f4a l i i g I \ 4 a c h i n eo t a r y e r oP o s i t i o( l v l R Z P ) R Z n Nesting sitions, Po ......21 ............26
RotaryTableDynamicFixtureOffset . . . , , , , , , , . . . . . 27 H e a d / T a b l e M u l tl i4ai xliisl v l a c h i n e s . . . . . . . . . . . . . . 3 1 l ng H e a d / H e M d l t i a x i s l v l il l4 an g i n e s . . . . . . . . . . . . . . 3 6 au li ch F i n d i ntg e P i v o D i s t a n c e h t 4 - A x i ls\ 4 a c h i n e s ......37 .............3S
Genemll4aintenance Issuesfor 14ultiaxis & lYachines . . 40 . I\4illing l4achines With 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 n d e x i nv l e t h o d s l g ........,,.51 56 H I W H o wC A D / C A |S y s t e m s a n d l e n d e x i n g o r k . . . . . . . . VI Machine Coordinate Systems. . lulachine Home Position . . ActiveCoordinate System . . , I\4achine RotaryCenterPoint , . SystemOrigin . . . CAD/CAM coordinateSystems . lYachine and CAD/CAM Synchronizing
O*=
60 60
Chapter 5: SimultaneousMultiaxis Toolpaths. ,65

T h eO p t i m uW o r k n v e l o p e E m Feedrates. I n v e r s e m e e e d r a,t.e Ti F P o sP r o c e s s o r s . t ............70 .......,,72 .......,,,...74 ....,........76
Chapter6: Commonsimultaneous Multiaxis cAM ,.....79 Toofpath ontrols C . C uP a t t e r n s . t

T o oA x i s o n t r o l . l C T o oTl i p o n t r o l . C C o l l i s iC o n t r o l on
.......79
............ 86
.............90 .............93
A d d i t i o n aL 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 M l D o v e t E f lf e c t . ai C u t t i n gi r e c t i o n D I v l u l t i aR os g h i n g . xi u ....,.......98 ..........100 ........101
C h a p t e r TM a c h i n e S i m u l a t i o n . . . . , . . , , . . , 1 O 3 r
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 . . . 0 ,5. . . . . 1. C o n f i g u r i n g V i r tM aa lh i n e so r S i m u l a t i o n . . . . , . . . . 1 0 5 Lr c F VirtualMachineBuilding...,,......,...106 T h eS k e l e t o n C o m p o n e n tss.l t 4 o d e. l.s v . M a c h i n ei m u l a t i Ionnt e r f a c e s S . U s i n M a c h i n e m u l a t i .o, n . g Si . .....106 ...,......I07 .........116 ...,,....7I7
Chapter 8: Selecting The Right Machine For your Application ...........119 Head/Head Machines (with long X or y - axis linear travel, b u t l i m i t e do t a r ya x e s r a v e l ) . r t . ......,.I21 Head/Tablel4achines(with long X-axis travel) . . . . . . . I23 H e a d / T a b l e c h i n e .s l4a ,......126
R o t a r T a b l e T i l t i n gH e a d o m b i n a t i o n.s . . , . . . . 1 2 8 y C . . T a b l e / T a b v ea c h i n e s . . lli G a n t r y y p eH e a d / H e ald l a c h i n e s . . T v ..,....I32 .,.... L34
Chapter 9! Choosing a CAD/CAM System For your Appfcation. i ..,,.,..,,,tg7 S p e c i P lu r p o s e f t w a r . . .. . a So e C A D / C A Io o l b o x . T 4 ... ..,,.. f37
.,......,,139 139
MultiaxiscAD/CAlvlConsiderations .,..... M u l t i a xC s f 4 . iA l 4 u l t i a xCs D / C AT4 a i n i n.g. , , i A I.
.,...I4O ....,,..I44
Behindthe Scenes:CAD/CAM SoftwareDevelopment . 145 . GeneralGuidelinesfor Researching CAD/CAM Software. . 146
Chapter 10: Putting ItAII Together, . , , . . . . .149

W h y U s e l 4 u l t i a x i s l v l a c h i n i n g T e c h n.i.q . .e .s. ? .. .u . W h a ti s a S t a n d a rs - A x i s\ 4 a c h i n e ? d l 152
......153 154
W h a t i s t h e S t a n d a r d A x i s C o n v e n t i o .n ?........ . ..
What are the ThreeMajor Multiaxis f4achine Types?. . . 154 What are the l'.lajor BuildingBlocksof a CNCl4achine? 1 5 6 . What are the 14ost ImportantPhysical Positions a of [4ultiaxis 14achine? What Toolsare Needed FindMRZP?.. . to 157 159
Description Indexing/Rotary of Positioning Work. . . . . . 1 5 9 Whal i5 a PostProccessor?. DefiniLion an Axis of Defining Simultaneous a 5-axisToolpath 159 160 160
Whatare the ThreeCommon Simultaneous lYultiaxis CAM Toolpath ConLrols. 161 14ultiaxis Machine Offsels.. . FindinglYachine RotaryZero Posilion. . . Finding the PivotDistance I n d e x i n g / R o t a r y P o s i t i o n W o r k O v e r v i . . w. .. .. . e. 167 162 164 166
Pickinga CAD/CAM System for Multiaxis Work . . . . . . . 166 14achine Simulation . Conclusion 167 767
Introduction
Are you utilizing5-axismachining? Couldyour shop benefitfrom the efficiency and powerthat 5-axismachining offers? The majorityof peoplenot embracing this technology lacka true understanding 5-axispractices. of Thereare many common misconceptions the subject,and the intent of this book is to demvstifv5-axis on machining and bring it within the reachof anyoneinterested usingthe technology in to its full potential. presented this book was gatheredduring The information in 30 yearsof hands-on experience the metal-working in manufacturing industrybridging countries, continents, (both human and G-code.) and multiplelanguages The authorworkedin Hungart Germany, Canada, and the USA,specializing in multiaxis solutions, spent many yearssettingup, programming, He and reparnng CNCequiprnent,and has used a number of different CAD/CA|Y systems. He has workedas a self-employed multiaxisconsultant, well as djrecuyfor CGTech (the as makersof VERICUT@) CNCSoftwareInc. (the makersof ttastercamo.) and The authorhas instructed countless multiaxis trainingclasses over the past decade, Theseclasses covered topicssuchas operating programming CNCequipment, CNCequipment, both manuallyand with CAD/CAM systems,and bujldingvirtual machines with differentverification systems.Throughthe years,the author has met many professionals aroundthe world and has come to a realization that they atl havethe same questions, misconceptions, concerns, and when it comesto 5-axis machining. The needfor unbiased information the subjectbecameapparent. on Up to this point,the best way to get information 5-axismachining on was to talk to peersin the industry in the hopethat they would sharewhat thev had learned, Visitingindustrial trade showsand talkingto machine tool and CAD/CAI4 vendors are other options- exceptthat these peopleall give their individual pointsof view and will promotetheir own machine solution.Everybodv or claimsto havethe best mouse-trap, and it is left to the individual choose to the right one. This book is not a trainingmanualfor any particular machine CAD/CAM or system. Rather, is an overviewof multiaxismachine it tyDesand the commoncontrol methodsthat CAD/CAM systemsuse to drivethe machines. The book will guideyou throughthis realm,from basicto complexconcepts, and will provideinformation to helpyou choose the right tools, including the machine, work-holding method, CAD/CAM system,and machinesimulation package that will best suit your specific application. The bookcontainsnumerous illustrations help you to precisely to implement thesetools.
History of S-Axis Machines

LongbeforeCNCcontrollers appeared,4-5-6-12and more-axismachines, referred to as multiaxismachines, were beingused.Ihe individual axeswere controlled mechanically through leversridingon cam plates.Some machines had more than 12 cam plates,controlling onJytool/tableand rotary motions,but also clamprng not and unclamping work-holding of fixtures.Thesemachines were cumbersome ano atme consuming set up, but they were perfecUy to suitedfor mass production. The first NC (numerical controlwithout internalmemory) machines were cumbersome set up and operate,but they also were great for massproduction. to At first, only the most affluentand established shopscouldaffordthem. programm,ng was a lengthy, process. error-prone Soon,machinebuilders addedintern;l memory to their controllers, then they addedthe abilityto executesimplebranching looping logic,and to calJ subroutines from other subroutines. was possible us; these It to macrolanguages directlyon the machine and to quicklychangeset_Lrps, especially for familytype parts. Differentmachinebuilders developed varioussoluiions, which createda numberof CNC(computernumerical controlwith internalmemory) programmrng tanguages. Companies with familiarnameslike Fanuc, Acramatjc, Heidenhein, Siemens, I\4azatrol, etc., all developed their own languages, but thesequicklybecamean issue.Some shopsran ten machines wiih eigfrtOifferent languages. a repeatjob came in, and the originallyprogrammed If michine was bus, a new programwould haveto be re-writtin from sc-ratch because the of language differences. N.ext,-the first.rudimentary CAD(Computer AidedDesign)/CAM (Computer Aided lYanLrfacturing) systemswere devejoped. first, these software At soluiionswere introduced the same companies by that developed controllers. the Soonafter, enterprising individLrals wrote their own CAD/CAI4 software. Thisjump in tecnnorogy was huge because allowedengineers draw their parts in a CADprogram, it to generate toolpathin the CAMsystemt genericlanguage, a and then translateit into multipleG-Code quickt, usingthe appropljatepost processor. languages This progress meantthat CNCmachines were no longerthe exception, and tney startedto becomethe norm. They were no longerusedonly for mass_production and they became versatile, accurate, and affordable. Ivlultiaxis machines went througha similarprocess, but because thev were more complicaled, this process look longer. First,Ihe machines were expensive to
purchaseand maintain, and harder to program,Only large aerospace companies had the need, the money,and the personnel handle multiaxisapplications. to Some companieskept their own processes closelyguardedin 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 softwarepossibilities and hardwarerestrictions. Today,there are many machinebuildersofferinga variety of multiaxisequipment quality,and price. Computershave becomevery in a wide range of configurations, affordable,and CAD/CAM systems now offer excellentmultiaxiscutting strategies with great tool control and large post-processor libraries.As a result, even smaller shopscan, and do, implement multiaxis machining. production Mostmachine builders are expanding and embracing new technology, Many believethat it is imperativeto competein the global market, especially againstcountrieswith abundantcheap labor.This attitude has resultedin increased multiaxis machine salesand some machine builders now havewaitinglistsof customers multiaxismachines, for Multiaxis machining a constantly is expanding possibilities. field,with almostendless
Common Misconceptions
Most peopleassociate the word "s-axis" with complicatedmotions such as those pump illustrated Figures for the induction in 1-1 and 1-2, and the programming techniquesneeded,This view is reinforcedby visits to any industrialtrade show to see both machinebuildersand CAD/CAM vendorsshowinooff their most complicatedcreations.
Figures 7-7 Example inductionpump set-up of

Secretsof s-Axis Machining
Figure I-2 Exampleof induction pump design. In reality, majorityof s-axisusersdon,tevermakean impeller, finish the or portsfor a.racing-engine cyrinder head.Mostof them machine parisusingsimpre 3-axisdrilling, contouring, pocketmillingroutines, and whileroiatingthe-part' occasionally a rotaryindexing in mechanism, illustrated Figurei1-3 and 1-4. as in very elaborate partscanarsobe machined apprying surfa-cing by 3D and - toorpaths engaging partfrom different the angles indexing rotarytable. by a
Figures t-g and l-4
Examptesof positioning work.
Usinga multiaxismachinewill greatly simplify the motions required,the programmingeffort, and the amount of fixturing neededfor machiningcomplex workpieces. other benefitsincludethe eliminati-on multiple set-upsf increased of accuracy, and better surfacefinish.
History s-AxisMachines of
I common Misconceptionr don't ilo enough S-axis work to warrant

a S-axis machine.
to Manyshopsare currentlymakingparts by movingthem manually different fixtures on 3-axis machines.Comparedwith this procedure,productioncan be greatlywithoutmuch effort by usinga 4- or a 5-axismachine. simplya If increased indexing tablewas added,only slighteditswould be needed single-or dual-rotary files.ExamDles shownin Fiqures 1-5 and 1-6. to the CNC-code are
Figures 7-5 and 7-6 Third-party rotary mechanisms. machining requires thinkingin spaceinstead in a flat plane. of Moving multiaxis to for work Dedicated multiaxis machines have beendeveloped the kind of indexing Figures 1-7 and 1-8, usingtombstone type fixtures. shownin the accompanying
Figure 7-7 Example of tombstone fixture.

Secretsof s-Axis Machinino
Figure 7-8 Example of 4-axis positioning. Onceyou enterthe multiaxis realm,new doorswill be openedfor your shop.your company will quicklybecomemore adeptand ableto tacklemore comDlex work. Before too long,your shopwill start takingon more and morejobs, and will need to be exoanded. Common Misconception: S-axis CAD/CAM is too expensive and is hard to use, The abovestatementswere true in the past, but not any more. If you currenfly own a CAD/CAM system, there is a good chanceyou already have s-axis positioning capabilities. MostcAD/cAMsystemsinclude thesecaDabilities their in basepackage. Manytimes, it is just a matter of trainingthat is needed get up to a n d r u nni n g . When you are shoppingfor a CAD/CAM system, make sure to chooseone from a reputable company with a commitment trainingand localsupport.Remember to that a CAD/CAM system is just another tool in your tool belt. you can buy fancy tools that are very capable,but they are worthlessif Vou don,t know how to use them. Great localsupport may very well be the most important feature of vour new tool.
Historv s-AxisMachines of
will be If you do a lot of simultaneousmultiaxiswork, the price of the CAD/CAM but you will be ableto charge only a smallfactor.Moretrainingwill be needed, time. The'hardto use'paft alwayscomes almostdoublefor your hourlymachine down to training - was it easy to learn how to operateyour first CNCmachine? job. simultaneous If world by startingwith a complex, Don'tenterthe multiaxis you alreadyown a 3-axismachine, tableand start with a single-or dual-rotary and you You will make parts faster and more accurately, apply indexingtechniques. Whenyou decideto buy new equipment, will be ableto investin more equipment. purchasewith the machine'spurchaseorder. see if you can bundlea CAD/CAM system speaksyour specific This is also a good time to make sure your CAD/CAM machine'slanguage- in other words, that it has the correct post processor. whichensures that their with a turn-keysolution, Somecompanies buy equipment job will run on the machineupon deliveryfrom the manufacturer. Many specific who in engineers, employcapable teamsof applications machine tool builders developers, Together, teams determinethe the turn, work closelywith CAD/CAM most efficientway to machineany specificpart, basedon many factors such as; quantity, tolerance requirements, toolingavailability. and material,
Reasonsto Use Multiaxis Machines

Reduced Set Up work One important reasonto use multiaxismachinesis to reduceset-up time for parts such as those shown in Figures1-9 and 1-10. Extra custom fixturing for secondary Most parts can be manufacturedin operationsis very costly and time-consuming. one or two set-ups, eliminatingthe need for extra fixturing and time.
Figure 7-9 Example part requiring positioning multiaxis machining.

Figure 7-7O Part requires two separate set-ups for machining. 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 (stacked)errors betweenmachinedsurfaceswhen they are milled to build up in multipleset-ups.The use of indexingrotary tables, or dedicatedmultiaxis machines, shownin Figures as 1-11 and 1-12, allowsprecise movement short, of rigid, high speedcutters for the best cutting engagement.More aggressive cuts can then be taken, with higher RPMand feed rates, while the highestlevelsof accuracy are maintained.
Figurc 7-17 Dedicated dual-rotary machine set-up.

History s-AxisMachines of
Figure 7-72 Dedicated dual-rotary machine set-up. Better Surface Finishes Usingshortertoolswill causelesstool deflection, whichwill minimize vibration and producesmooth, precise,cuts. When using ball-nosecutters it ls recommended that the contact point be moved away from the tip of the cutter that isn't spinning. By tiltingthe tool, as shownin Figures 1-13 and 1-14,the workpiece can be engagedby a desiredcutter area, which will not only improvethe surfacefinish and repeatability, but will also greatly improvetool life.
Figures 7-73 and 7-74 Machiningparts such as fhese requires simultaneous cuttino motions.
10
Secrets s-AxisMachining of
Open New Possibilities some partsare impossibre cut on a 3-axismachine. to other partswourdtake too many set-upson a 3-axismachine be profitable. to Onceyour shopgets comfortable with indexing work, you will be able to start machining part; suchas thosein Figures 1-15, 1-16, and 1-17, usingsimurtaneous murtiaxis motions, and openyour buslness many new possibilities. to
Figures 7-75, 7-76, and l-t7
More examples of parts that require simultaneous cutting motions.
A word of caution: Simultaneous multiaxiswork is inevitably Jess accurate than indexingwork because the machinemust be run in a loose mode with the rotary drives unlocked.It is recommended that all possible roughingoperations done by indexinq be the rotaries optimum angles,because to the machinein lockld mode is much more rigid.This type of work is also called2+3 machining.The two rotary axes are first positionedand locked into the optimumattack position, then a standard3-axisprogramis executed.
History s-Axisl\ilachines of
11
Know Your Machine

Whatdo you picturewhen you see the words"standard s-axismachine?,, lvany industry buzzwords usedwhen describing are s-axismachines. Someof them include: gulde-ways, staggered constant dynamiccontrol,digitalAC servomotors with pre-tensioned permanent ball-screws, positioning monitoring system,maximum utilization layout,long-termaccuracy, and so on. To simplify things,we will say that thereare three major building blocks thesetypesof machines. to
The physical properties of the machine The physicalpropertiesof the machinedescribethe wav tne axes are stacked, rigidityand flexibility the iron,the horsepower, the of torque, and maximumRPMof the spindlemotor,the qualityand workmanship of the guides/slides, the rotary bearings. and The CNCdrive system The drivesystemis the muscles the components or that makethe machine slidesand spindles move.The systemincludes servo the motors,drivesystem,ball screws, the way positioning controlled is and monitored, and the rapid-traverse feed capabilities. and CNCcontroller capabilities The controller the brainof the machine. is Data handling, available onboardmemorysize,and dynamicrotarysynchronization controls, are someof the thingscontrolled here. The perfect combination the abovecharacteristics builda fast, accurate, of will easyto-program and operate,s-axis CNCmillingmachine. lvanymanufacturers have spentmany yearstryingto come up with the perfectcombination, as a result and there are manVvariations and solutions. The lllustrations Figure in 2-1 showsomeof the varietythat existsin the machines that make up the CNCmanufacturing industry.
13
Figure 2-7 Typical arrangements of multiaxis CNCmachines.
Multiaxis Machine Configurations

The arrangements shown in Figure2-1 are all very popularconfigurations, but none of them is "standard."There is no such thing as a standardS-axis machine. First, let's establishthe definitionof an axis. Any motion controlledby the NC controller, either linear or rotationalis considered axis. For instance,in the an iflustration Figure2-2, both the spindleheadand the quill are capable moving in of in the same direction,but are controlledby two separatecommands,Movementsof the head are controlledby Z and those of the quill by W.
Figure 2-2 The spindle head and the spindle quill move along parallel axes.
14
TU
Secrets s-AxisMachinino of
The terms multiaxis and s-axisare often usedinterchangeably theseterms and can be confusing. The widelyrecognized term in the industryis 5-axis,but it is g-axisstandardpossibilities misleading because exist - withoutaddingadditional sub-systems. addition, 4-axismachine alsoconsidered be a multiaxis In a is to machine. Despite title of this book,the more accurate the term multiaxis will often oe useo. The following provides list the industrystandard nomenclature the basicg-axis for desig nations and directions.
XYZ are linearaxeswhereZ is aligned with the spindle the machine. of ABC are rotary axes rotating aroundXyZ respectively. UVW are parallellinear axes along XyZ respectively.
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 purchased and 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. Everymachineis a compromiseof some sort. Rotational directions,start positions, and limits, will be differentfrom one machineto another.The effectivework envelopeis greatly modifiedby changingthose variables,Some rotary axes can rotate in both directions.Some axes will choosethe rotary directionbasedon the existingposition- shortestdistanceversus clockwise(CW) or counter-clockwise (CCW).Some machinesthat are equippedwith dynamic rotary fixture offset mode will move the linear axis while rotating the rotary one basedon a rotary command. To understandthese machinescompletely, is necessary look at every machine it to as a uniqueentity, to look under the skin and understandhow the skeletonis constructed, You need to know where all the joints are, where the rotary axes are, where the rotary zero positionsare, what makesthem move, and how the whole unit functions unison. in Differentmanufacturers and CAD/CAM systemshave many different namesfor the same things. Let's establishsome commonterms that will be used in this book in order to avoid assumptions and confusion. Machine Home Position (MHP) - Most machinistsrecognize the home position as the placeto whichall the axes movewhen you initially turn the machine and on selectZero return.
Figure 2-3 Machineat Home PositionX0. Y0. 20. A0. 80.

16
MachineRotary Zero Position (MRZP)- On multiaxis machines, machine rotary zeroshownin Figure 2-4, is at the intersection the rotary/pivoting of axes.This pointmaybe unreachable the machine. by
Figure 2-4 Close-upshowing MachineRotary Zero position. lrogram Zero Position (PZP) CAM system. - program Zeroposition the part datumin the is
Figure 2-5 Another view showing the relationship between Machine Rotary Zero Position and program Zero position.
KnowYourMachine
17
Whensettingup/ operating/ and programming multiaxis machines is essential it to maintain the properrelationship between (MRZp) and the machine zero position the programzero position (PZP). If the machine doesnot havespecial features then the PZP must coincide with the MRZP. lYultiaxis millingmachines can be organized furtherinto 3 major machine types:
Table/Table multiaxis machines execute the rotary motions by the dual rotary table, The primary rotary table carries the secondary rotary table, which in turn carries the fixture and the part. Head/Table multiaxis machines execute the rotary motions by the table, which carries the work piece, The spindle head articulates the tool with tilting motions. Head/Head multiaxis machines execute all rotary/pivotang motions by articulating the spindle head of the machine, The work piece is stationary.
Keepin mind that the focusof this book is milling,although the line between the mill and the latheis blurringmore and more everyyear.Thereis a new breedof multi-tasking machines available that can do millingand turning,and thoseare calledMill/Turn machines. Forthe sakeof simplicity, will focusonly on multiaxis we millingmachines.
Table/Table Multiaxis Milling Machines

Table/Table multiaxis millingmachines can be vefticalor horizontal. the All rotarymotionsexceptthe spindle are done by the tablesof these machines. The main rotarytable carries secondrotarytable,as shownin Figure2-6, to whichis a fastened fixtureand the Dartto be machined. the Toollengthoffsetswork the sameway hereas with anv conventional 3-axis machine. The tool lengthcan be changed withoutthe needto re-postthe NCdata. On thesemachines, part is physically the rotatedaroundthe tool. The machine's rotarydevices needto be capable handling weightof the part and the of the fixture,and this capabiiity an impodantfactorwhen rapidmovements is are considered. Anothervariation seenin Figure is 2-7. The examples shownrepresent only a smallfraction the available of Table/Table variations. Mostof thesemachines haveminimumand maximumrotarv limitson
18
oneof the rotaryaxes.somewill haveunlimited ry motionon the otheraxis. rota Someevenhavethe capability spinthe work,as a lithe woutd. to Table/Table machines the mostcommon are typesof murtiaxis machines. Most people enterthe s-axisworldby purchasing-a will single- dual-rotary or device and boltit to their3-axis milling machine
Figure 2-6 Simulation of a dual rotary mechanism fastened to the tabte of a standard 3-axis CNC milting machine.
Figure 2-7 A third-partyrotary mechanismfastened the tabteof a standard to

3-axis CNCmilling machine.
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 manufacturers use specialized dual rotary mechanisms. in Figure2-9, which is designedfor machininginternal such as the one shown enginecomponents. combustion
usedin enginemanufacture. Figure 2-9 Specialized dual rotary mechanism

20
Dedicated Table/Table machines very capable doingindexing/position are of ing work and are equarry capabre simurtaneous of work. The inherent diflerences between two are worth mentioning. the The rndexing method hords the workpiece much more rigidry than it is herdfor simultaneous machining work because rotaryaxesare-rocked the when machining. when rotatingan axis,the rotaryaxis must firsl be unrocked with a designateJ M-code. The axis is then rotated,and it is rocked with anotherM-Code b-efore machining resumed. is This sequence allowsmachining be done in the machine,s to most rigidstate. when usingsimurtaneous mi||ingtechniques, the brakesmust be disengaged, aI whichwill put the machinein its roose mode.Forthis reasonit is arways g-ooi u ideato use (when possible) indexing/position millingtechniques roujhing ing foi cuts.
Machine Rotary Zero position (MRZp)

Commonly, MRZP represents the intersection point of the rwo rorary axes, althoughsometimesthe two rotaries may be offset by a specificdisfance.This distance must coincide be relative the part datum pZp (program Zero or to Point) of the CAMsystem. To accurately up, operate, set and programthesemachines, is necessary it to find the intersection the rotarycenters the machine of of axes.some. but not ali, manufacturers have the varuesstampedon their rotary devices.However, those numbers are not to be trusted,and must be recalibrated regularly.
Finding the precise center of rotation is the foundation of accurate work.
Evensmalldiscrepancies magnifyerrors.furtherawayfrom this machine will rotary zero point.
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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.
2. Find the XY zero, using the dial indicator, Zero xy and A at this point, as shown in Figure 2-13,
Figure 2-73 ZeroingXY and A positions the work-holding on table. 3. RotateA+9O degrees and touch the OD of the table as shown in Flgure 2-t4,
Figure 2-74 After rotating the A axis through 90 degrees, touch the outside diameter of the table with the dial indicator.
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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 of Secrets 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 intersection the dual rotary center lines is abovethe table in of the examplegiven.This locationwill be differentfor every machine,even from the same manufacturer. is imperativethat this positionbe checkedregularry, It especially aftera heavyworkload a crash,Smallmisalignments causeiarqe or can errors because the tool positionis measuredfrom this intersection point. All the Active coordinate systems also referredto as Nesting positions or Locaf Coordinate Systems, for example G54 - Sg, are relativeto the Machine Rotary zero Point (MRZP) position.It is good practiceto set one of the nesting positionshere, so that it will be capturedin the Registry allowingit to be recalle-d quickly, usingMDI (Manual Data Input). F o re x a m p l ec 9 0 c 5 4 x 0 . y 0 . A 0 . c 0 . :
The PZP(Program Zero point) of the CAM systems mustbe set exac v to the MachineRotary Zero point, as seenin Fiqure 2-19.
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Figure 2-78 Relationshipbetween the MRZPand the PZP. 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.
Figure 2-19 Sketchshowingsomeofthe many localcoordinatesystemsusedin programming. CNC

The advantageof using these Locar.coordinate systems is that you can easiry followthe programon the controller,s displaysc.eenbecause absojute the valuesshown there will reflectthe valuesrelativeto each locally-nested position. Z+1.000,for examplewill be 1.000(inch)abovethe part face. Despitethe fact that cAM systemsa use different naming conventions their for coordinate systems/ they alr handre the rocar coordinate systemin a simirar way. Some.ofthe names used by_ CAD/CAM systems include:p'art Datum, Active Coordinate System, Local Coordinate System, System View, and Tool plane with an Origin. The disadvantage using a number of different rocarcoordinatesystems is the of potentiar misarignment for when pickingup thesepositions manuairy with a dial indicator.Many programmersus_e only _one coordinatesystem for S_axis wort<. itrey usethe MachaneRotary zero point (MRzp) as the pirt datum and ret either the cAN4 system or the machine'scontroler carcurate speciarrou"r"nt. the nui"iruiy. If a part is placedin the same position the cAM and in the machine, in the ciM i;' very capableof generatingthe correctcode. The advantageof using a singrecoordinatesystem is that the part needsto be indicated only once.The disadvantage that it is harderto visuallv is followthe programon the controller'sdisplayscreen.The system will have to be switched over to Distance to Go for safer operation. using a real s-axis machineas a verificationsystem is inefficient,cumbersome, -' and very dangerous. Thereare many machine simulation softwaiet;.k;&; available that can savea rot of time and money,and theseare covered another in chaDter.
Rotary Table Dynamic Fixture Offset

The Problem cAM generates,code a given positionof the programzero point (pzp) rerative for to the centerof rotationmachinezero point, (MRZF). The machineoperito,.may th: c.ogg later,on the night shift, at a differenttocation ApZp (Actual part lun Zero Point). He or she may not be able to placethe part exacflywhere the CAD/ cAM programmerintendedit to be. If the operatordoes not havethe access tire or abilityto make the change,then the job wiri haveto wait for a repostedcodeto be supplied. ModernCAD/CAM systemscan easilycalculatenew code if the part is moved. But as previously mentioned,the part will have to be moved to exacflythe same positionin the cAM system and then the code wil have to be recarcurited. 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 the discrepancy for between the two positions. This optionis called
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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 machiningcan be executedby setting one point convenientbecausemultiple-face as the referencewhen machininga complexworkpiece.
Figure 2-2O Potentialproblems in establishingthe rotary table dynamic fixture offset (RTDFO). Thereare 2 wavsto use RTDFO: 1. Set the fixture offset amount manually on the Fixture Offset screen of the machine,illustrated in Figure 2-21,
28
rey E-1grylo1selection E (oFFSET) --+

OFFSETI IFIXTURE
Figure 2-21 A Fixture Offset Screenon a CNCmachine. 2. Specify the values in the machining program (G-Code). The fixture offset amount is the distancebetweenthe rotationaicenter (MRZp) and the workpiecezero point, used by the CAMprogram as the programZero (PzP).
GlO L21 Pn X_Y_Z_B_C_ n X_Y_Z_B_C_ Fixture offset number (1_g) Fixture offset amount for each axis
When usingthe c90 mode/the specified valuesare set. Whenusingthe G91 mode,the sums of the specified and the previous valuesare set.
KnowYourlvlachine
29
Activatino RTDFO: G54,2 Pn; G54,2 PO, n RTDFO- ON RTDFO- OFF
Fixture offset number (1-8)
The G-Code belowshowsan examDle:

00001 { P,ROGT?Ar, ZERO ) ( D]TE A2 ]i A7 TINE G21 c0 G17 G40 cac c90 G94 G9a 00001 { P.eoGr?Ai,- cLoNE2 ) ( DA?a O2-i1-07 TIME A7:22 ) G0 c17 G40 G80 G90 c94 G98 c28 XO. YO, BO, 3) D.aa. oii. I rooL ( G13.4 G5 Pl0O00 ) T3t M6 c90 Go 2500. s0. co_ c 43 . 4 ! 3 1 2 2 s 0 . G54 - 3.1 ,,rN_ 3) Dra. ( laoL 31 Dra. a!F. ( c43.1 G5 P1A0O0 ) T3t M6 090 60 2s00. B0. c0. c 43 , 4 f l 3 1 2 2 5 0 . G05 P10000 G54 3:L LEN31
07:22 )
M69 c90 G0 x13?.043 y3.53? C-31.266 818.001 St'ttat t\13 293.4 ,-1 G 1 5 3 3 . 4 r 7 F : ' :0 . . . r , 1 3 5 . 3 4 6 y 3 . 2 5 3 2 8 3 , ? ? 6 C 3 1 . 6 4 A 1 3 . 2 0 9F ; 0 0 D . " < t 3 4 . 6 3 9v 2 , 9 2 3 ? 8 9 - 0 3 ? C - 1 . 9 9 ? 8 1 9 , 3 2 4 x133.464 y2.526 289.:,!4 C-82.331 818.413 xt32.321 12.061 239-335 c 32-639 Bla.4t6 x l 3 0 . 9 8 3 y l . 6 0 5 2 3 9 . ? 3 4C 3 2 - 9 4 6 8 1 8 . 6 5 2 r1,29.46y1-382 290.424 c 83.335 816.934 x!2).122 y7,54 ?91,324 C-83,869 319.316 x125.t38y2.196!92-504C-!4.591B19,?4 x124.06? y3.421 293,492 C-E5-439B20.334
M69 r G 9 0 G 0 x l 3 7 . 0 S 3 v 3 . 5 3 7 c - e l . 2 6 6 8 1 E . 0 8 1 s L 0 a i : ; a' 1 3 2 1 8 8 4? l , 29'.. 411 j Gt 244.471 ?2n14. x135.846 y3.258 ZA3.??5C 41.64 814.209 Fri0trC_ x , L 3 4 , 6 3 9y 2 . 9 2 3 2 8 ! . 0 3 ? C - e 1 , 9 9 7 B 1 8 , 3 2 3 tt33.464 v2-526 2a9.244 C-32.331 B18.4!3 x l 3 2 . 3 2 1 y 2 . 0 6 1 z A 9 . i 3 s c 3 ? . 6 3 9B 1 3 . 4 7 6 x130.983 y1.606 ZA9.?33C 82.946 B13.652 . A 1 2 9 . 4 61 7 , 3 4 2 2 9 0 . 4 2 4 C - 8 3 . 3 1 5 8 1 8 . 9 3 4 xt21.722 r1.54 291,:24 C-83.869 819.31. tL2a.73a v2.796 292,504 C-S1,591 B19,874 tr24.061 v3-421 29t.492 C-45.439 824.334
Figure 2-22 Example of G-Code data for setting RTDFO. If the machine doesnot havethe optionmentioned above,the CADgeometrywill haveto be moved,and the G-Code re-posted the CAMsystem. in Notethat the aboveexamDle for Fanuc is controllers. Othercontrollers havea varietyof namesfor this and similarfunctions.
30
Secrets s-Axis of Machining
Head/Table Multiaxis Milling Machines

havea rotarytableand a tilting head. As their name suggests, these machines
Figures 2-23, 2-24, and 2-25 Example of Head/Table multiaxis milling machines, which have rotary tables and tilting spindle heads.
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Head/Table machines arguably are the most capable the three groups of illustrated and can machinelarge,heavyparts.On some machines, rotarvtable the can be supportedby a steady rest and it rotatesthe paft only around its own axis. The pivoting spindleheadcarries the weightof the tool. It needsto be capable of handling the cuttingpressures it is manipulating tool. as the Thesemachines also well suitedfor both indexing are and simultaneous work. Some havethe capability calculate to axis substitution internally, enabling the user to programparts in the 2D flat planeand then wrap the planearounda specified fourth-axis diameter, How does axis substitution work?
Axis substitutionis shown in Figure2-26, and is effectedby the following oroced re. u lYeasure A-axisdiameterand multiplyit by pi to find the circumference. the Drawa rectangle wherethe Y side is the circumference the X side is the and lengthof the part. Createthe cuttinggeometryinsidethis rectangle. Createa 3-axis toolpath, XYZ, and activateaxis substitutionby first defining the A-axisdiameter. On a Bostomatic controller, example, for this resultis achieved addingtwo lines by of code. G25 A3.OOO G131 A-axis diameter Axis substitution Y to A active
Figure 2-26 A part produced by means of axis substitution. After these blocksare read, all Y-axismoves will be replacedby instructions for A-axisrotarymotions. the machine If doesn'thavethis capability, same this processcan be achievedwith any modern CAD/CAM system. The rotaryaxeson thesemachines usuallyhaveunlimited rotarymotion.Some machines can evenspin the workpiece in a lathe.The secondary pivoting as axis has an upperand lowerlimit. In orderto accurately up, operate, set and program
32
these machines,it is necessary find the intersection the rotary and the to of pivotingaxes. Some examplesof machinesat the Zero positionare shown in Figures 2-27, 2-28, and 2-29
Figures 2-27, 2-28, and 2-29 Examples of machines with spindles at the zero Dosition, face Notethat withoutconsidering tool, all these machines the alignthe spindle with the center of the rotary axis while the pivotingcenter point is some distance away from center.This distanceis commonlycalledthe Pivot Distance. The Gage Length is the distancefrom the spindleface to the tool tip. 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.
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The machine's linearaxesalso haveto movealongthe X and Z axes in orderto keep the tool tip stationaryin spaceas it executesthe pivoting B90 motion. CAM systemswill makethe necessary calculations during"post processing.,,Some machines havethe abilityto calculate necessary the motionsautomatically, based on the offsetsshownin Figure2-31, captured the machine in controller,s reqistries.
PIVOT
= TANCE
rbor-rr'rerrt
COMPOFFSET
Figure 2-32
Multiaxis offsets.
Fanuc examole: G43.4, G43,5 s-AXIS ROTARYTOOL CENTERPOINT CONTROT(RTCP) If the Rotary Tool Control Point (RTCP)function is used in the Fanuc program,the spindlepositionis automatically adjusted in synchronywith all rotations,as shown in Figure2-33 and the listed code lines beneaththe figure. As a result, the relationship betweenthe tool center point and the workpiecewill alwaysstay fixed.
34
Secretsof 5-Axis lvlachining
Prog.amSpecifed
between the tool center point and the workpiece stav constant, G90 G54 c00 x0 Y0 B0 cot S-MO3 ; G00 G43.4 Z_H_; X_Y_B_C_t
G49; G43.4 . . . x,l ,z, Toolcenter point function (Type 1) ON
(G90) The coordinate . . . valueof 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 . . . c49 . Example: .
Tool length offset number Toolcenter point control function (Type 1) OFF
G90G00G54x0, Y0.80. s5000M03
C0.;
. M o v e sX , t ,
B, C to PzP
G43. 4 zL . H01; . Activate RTCP. Positions tool tip at Z+ 1.000 the while Z axis positionis offset by offset data set for tool length offset number 1.
Know Your l\y'achine
Some Head/Table machineswill use both RTCP(Rotary Tool Control Point) and RTDFO(Rotary Tool Dynamic Fixture Offset) simultaneously. While RTCP is offsettingthe tool positiona combineddistancefrom the head'srotary point (pivot distance+ gage length), RPCP is compensating the relativedistanceof the part for from the MRZP (Machine Rotary Zero Point) to the actual fixture position. If the machinedoesn't have RTCP,to avoid repeatedre-postingwhen tools are changed,it is common practiceto pre-set all tools to the same length when Dossible.
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, continuously or indexing. Someexamples shownin Figure are
z- 5+.
Figure 2-34 Examplesof Head/Head machines.

36
All Head/Head machines havedifferentbehavior; basedon indlvidual installation settings. Rotarydirections, limits,retractions, rotarywind-up,and handling singularities can all be alteredfrom factory settings.The most impoftant basic dimensionneededis the rotary/pivot center pointr which is measuredfrom the spindle faceto the head'srotaryposition. Machine manufacturers sometimes provide nominalvalue,but it is essential a that the manufacturer's value be double-checked/ especially it is a nice roundnumber, instance, inches. if for 10 The roundness a good lndication is that the numberis not accurate. "Close" is not good enough. Knowing the exact dimension is vital if precision work is to be done.
Finding the Pivot Distance

1. First,makesure that the machine head is in a perfect vertical orientation by touching the machine's table with a dial indicatolthen rotatingthe indicator. The indicator shouldreadzeroaroundthe wholecircleas shownin Fioure 2-35.
Figure 2-35 Indicating vertical position. 2, Place 1.000diameterdowelpin into the mastertool holderwith a known a Gage Length (GL). plungeras shownin Figure2-36. A flat attachment 3. Touch the dial indicator helpshere.Set the indicator zeroand recordthe Z valueon the controller's to screen. Let'scallthis valueZ maximum.
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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 minusdirections until you get to the position shownin Figure2-37.
Figure 2-37 Z minimum position. Record this Z valueon vour controller's screenand let'scall this Z minimum.
38
Youshouldhavethe following valueshandy: Z maximum Z minimum GL - Gage Length R - Dowel pin radius = .5OOO Formula to calculate Pivot Distance: PD=Zmax-Zmin-GL+R
This distance(PD). will be used by the post processor. Most CAMsystemswill drive the Pivot Point and they will have to calculatethe tool tip locationfor every programmedposition.The tool tip locationis the Pivot Distance plus the Gage Length away from the Pivot Point at all times, and must be triangulatedbasedon the rotary/pivotingangles.Evensmall discrepancies the Pivot Distance will be in magnified into largetool position errorsin the final program.
4-Axis Machines
If a third-pafty, singlerotary mechanism placedon a 3-axismillingmachine, is it becomes 4-axismachine. a The most oopular dedicated 4-axismachines the are horizontal typesshownin Figure2-38.
Figure 2-38 4-axis horizontal machining center.
Know Your Machine
work, wherepartsare clamped Thesemachines mostlyusedfor tombstone are to all sidesof the tombstonefixture and machinedby rotating them into different positions, because they fall away by The chipsdon't collect the work-piece on gravity and are cleanedoff by strateg lly-placedcoolantnozzles. ica whichis positioned outsidethe The examplein Figure2-38 showsa palletchanger, machine's allowing the operator loadworkpieces unloadfinished to and enclosure, partsduringthe machine palletchanger assemblies also are cycle.Elaborate jobs can be preavailable, with multiple tombstones whicha varietyof different on to loadedand made ready-to-run. This arrangement allowsfor quickchangeover a job withoutstopping new the machine.
General Maintenanceand Issues for Multiaxis Machines

It is recommended that all machine toolsbe kept cleanand free of objectsthat on can causedamage,and this rule is even more important s-axisequipment. regulartime intervals, and most certainly Realigning routines shouldbe done at kept of the machine's vital after heavywork, overloads, a crash,A log shouldbe or shouldbe instructed listenfor any new soundscoming to statistics and operators from the spindle(s) rotary mechanisms. or include: Somecommonoroblems . The rotary Sometimesthe rotary brakeswill fail and they won't disengage, mechanismwill then work extra hard to rotate from positionto position,and if fail. simultaneous work is in hand,the unit will eventually Someof theseapparent Somedual rotarytablecenterlinesdo not intersect. 2-39, and some are not. If the discrepancies by design, shownin Figure are as error is by design, is usually largenumberthat can be seenby it a apparent It that eye. If it is not by design,it won't be noticeable. must not be assumed Misalignment be can the centerlines in line,and they must be checked, are for compensated by inputtingthe relevantvalue into the post processor,
Figure 2-39 Example of rotary mechanismsplaced in offset positions by design.
40
Secretsof 5-Axis l\4achinino
Figure 2-4O These rotary mechanisms appear to be intersecting. Some Head/Head types of machineswill not run true. To checkthis aspect, arrangethe machinewith the secondaryaxis pointingdown verticallyas shown in Figure2-41. Then, rotate the primary axis through 360 degrees.The dial indicatorshould read zero throuqhoutthis motion.
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 highlighted when fast. simultaneous, multiaxis motionis beingused. A good-qualitymachinewill executethese motions quickly and repeatedly,in a smooth synchronized way, without one rotary axis waiting for anothel and without backlash vibration. or The rotarymechanisms haveminimalrun-out,and the will rotary centerlines will align precisely. Cheapermachinesmay execute positioning movements well, but will executesimultaneous motionspoorly. Many manufacturers will list "positionalrepeatability"in their specifications because it is a good measureof the machine'squality.One way to do a quick check of repeatability to set up an indicator the machine is on table,engaging tool holder the at zero.Then a ten-minuteroutineinvolving the machine all axeswith multiple rotationalmoves should be executed,terminatingwith returningto the start The indicator'sreadout retativeto zero is the measurementof the Dositional Dosition. repeatability. It is not necessary buy the most expensivemachine,but only to take a good to purchaseof a multiaxis look at current and potentialfuture needswhen considering machine.
42
Milling Machineswith Five or More Axes

lVostmachineswith more than five axes are built for specificmanufacturing applications, Some examplesincludethose shown in Fioure2-42:
Figure 2-42 Some examples of more than s-axis machine designs, It is possible assemblemultiple 9-axis subsystems, to and some manufacturers have built machineswith over 100 axes. Many of these axes are part of elaborate work-holdingsystems,and have parts that need to be rotated out of the wav of other machinecomponents during some manufacturingprocesses. Many such machinesare controlledwith dedicatedM-codes,which activate pre-set subroutines.
KnowYourMachine
E
a A simpleexample sucha subroutine an M06,whichcauses tool change. of is tool-changer: what happens any machine on with an automatic Observe closely locations;the tool-changecarousel the machineslidestravel to pre-determined the chosentool; a little trap door may open, dependingon the advances will exchange tool between the the spindle and the machine; then a swing-arm is carousel. This whole choreography 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,
44
Cutting Strategies
If drawings the same multiaxispart were givento five differentCNC of programmers, chances are good that they would come up with five different methods machine to the part. This variability a productof experience, is available multiaxis equipment, available CAD/CA[4 systems,tooling,fixturing,material,and quantities. What doesevery CNCprogrammer when askedto write a programfor a new do part? He or she will createa mental imageof the part, and basedon the above factors,go througha varietyof differentscenarios determine to how to machine it. Thesedecisions includehow to hold the part, and whichsideto start on. will The programmer then mentallygo throughthe whole process removingall will of the excessmaterial from the starting stock in order to free the desired part from within it. Mostprogrammers brainstorm will repeatedly and come up with multiple solutions, eliminating weakestones,addingnew ideas,and then makingthe the final decision. This whole process happens long beforethe creationof the actual toolpath. This pre-workmeditation the singlemost importantpart of the whole is process. manufacturing The process described aboveis the same,whether3-axisor multiaxis work is beingconsidered. The big difference usuallywith the fixturing.Work holdingis is amongthe first decisions be made when programming 3-axismachine.Many to a programmers placethe part data on a virtual machine. multiaxis will This process lets them levitatethe part in the air and simulatethe machine's motions,without a fixture present, see if all motionsare possible to withoutviolatingthe machine's work envelope boundaries. The part will be movedin spaceto achieveoptimized, synchronized motions.Finalfixture placement, design,might be one of the last or steps, Of coursethis procedure not alwayspossible, when a fixture is is but predetermined, additional effort will be neededto make sure there are no collisions between the fixture,tool, shank,arbor,or tool holder. Avoiding collisions a big is part of multiaxis programming. Collisions occurnot only duringcutting,but can palletchanges, manualretraction also duringtool changes, or movesafter an abrupt programstop. Forexample,after a powerfailure,the tool couldbe in a position wherethe onlVsafe retraction move is simultaneous multiaxismotions.
The singlemost importantpart of mu tiaxis programming the initialtime that is is spenton decidinghow to tacklethe job. I\4achining sequences shouldbe kept just because shop has the latestequipment, the the simple,not made complicated most powerfu CAD/CA[4 system,or an unlimitedbudget.Hereare some questions that needto be considered: How many parts are needed? How much time is available? what is the material? What machine is available? How good is the CAD/CAM system? How well do you know CAD/CAM? what tooling is available? Do you have to use existing fixtures or can you make your own? Ar there any special requirments?
Limitations applyto every too in the shop.The trick is to work aroundthose limitations. The difference betweena good multiaxisprogrammer and an average one is that the good one is industrious. one approach If doesn'twork, anotherone will be tried Lrntil the best solLrtion appears.Regardless the CAD/CA|4 of systemin use, many times extra geometrywi I haveto be createdto achieve the best resuts. Do the Prep Work in The time invested preparing in the work will be invaluabLe the ong run. once a decision has been madeon how the job wil be handled,it is importantto organize the work. Divideup the operations the CAD/CAM in systemand move necessary geometryto easily-recognizable named layers/levels. This preparation make it will possible isolateindividLral to featuresand allow a focusedworkflow. Make a Tool List It is very importantto make a tool list for any job. Start by analyzing the part geometrydiligently. Findthe smallest fillets.Measure how much room there is featuresto determinethe minimumand maximumtoo diameters that can between what tools are readiy available the shop to see if any of them in be used.Check If can be used,especially you are a readyfamiliarwith their performance. you if performance must ordertools,do some research their on and availability.
46
Secrelsof 5 Axis Machining
Determine Fixturing
Checkon available fixtures,vises,and clamps.Useexistingvisesand fixtures wheneverpossible, keepthe costsdown. The equipment to shouldbe modeledin the CAD/CAM systemand organized into libraries that can be readilyaccessed and loaded virtual simulation for when checksare madefor possible collisions.
CompareMachines
If more than one machineis available the job, some comparisons for shouldbe made.Amongessential checksare: work envelope limitations, maximum RPIY, feed-rates, and controller capabilities.
Know Your Stock Options

l'4aterial stocksmust also be considered. the materialis unfamiliar, If some research will be neededon differentcuttingcharacteristics. originalform may The be a billet,a cylinder, casting,or a forging,and may requiresome preparatory a work beforemachining can start.
Cutting Strategies
Indexing Multiaxis Toolpaths

Set-upsusing indexingor indexedwork are rigid and precise.Other common names and fixed rotary work. With usedfor such set-upsare 2+3 machiningor positioning, and cutting indexingwork, the rotary/pivotingaxes are used only for positioning, (machining) work is takes placewith only the three linearaxesmoving,Indexing the "bread and butter" of the multiaxismachiningindustry.Many parts are massproducedby this method, and it is the most basicmultiaxisconcept.It is an easy transitionfrom multiple set-up, 3-axis work to a single set-up indexingone, The graphicsin Figure4-1 show how one part can be cut from many differentangles without being removedfrom the fixture.
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.
Figure 4-2 Part of an aircraft landing gear machined with an indexing set-up.
The conceptmay be simple, but it allows for the manufactureof very complex parts with precision,like the samplesshown in Figures4-2 and 4-3.
Figure 4-3 An aerospacecomponent machined with an indexing set up.
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 indexingsequences every cycle.The cyclescan be activatedmanuallyor through at a dedicatedM-Code.If one of these methods is used, great care must be taken to synchronize the manual operationswith the Nc-code,Ample opportunitiesexist to make a mistakewith these methods. Figures4-4 and 4-5 show two examplesof custom indexingfixtures.
Figures 4-4 and 4-5 Two examples of custom-built, indexing fixtures.

IndexingMultiaxisToolpaths 5'l
The best method is to use fully-integ rated. 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). Figures4-6 and 4-7 show some examplesof dedicatedthird-party rotary mechanisms.
Figures 4-6 and 4-7 Examples of dedicated third-pafty rotary mechanisms. The best approach to use a dedicated is multiaxis machine, one is available. if Thesemachineshave brakeson their rotary/pivotingaxes, which provideextra rigidity during cutting. Typically. these brakesare releasedwhile positioning changes made,but oncein position, are they are re-engaged that the machine so can stay in its most rigid state for cutting. Some machinesare not numerically (for example, controlled are capable indexing but of only in certainincrements 1 degree),and they often operate by lifting away from a serrateddividing plate duringindexing.
52
Figures4-8 and 4-9 show some examplesof dedicatedmultiaxismachine,rotary mechanisms.
Figures 4-8 and 4-9 Some examples of dedicated rotary machine components. On some machines, spindleheadscan be changedrepeatedlybetweenoperations. The examplesshown in Figure4-10 can be straight, set at a specificangle, or even adjustedsteplessly variousangles. to
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 medical industries, designed and aerospace are to indexand hold the part with gripping axeswhile machining. Examples these of 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. Plainindexingis a very efficientway of moving parts into positionfor machining, especially when it is combined with pallet-cha nging.A palletchanger can be as simpleas a singlerotaryindexing mechanism. can also be as complexas It jobs, runningin a prea multi-pallet conveyer, with not just one, but multiple organizedsequence. Thesesystemsare so flexiblethat a brand new job can be introducedinto the queue without stoppingthe machinesequence, shown by the as examplesin Figures4-L3 and 4-L4.
54
Figures 4-73 and 4-74 Brand new jobs can be introduced into the queue without stopping the sequence with these pallet-changing machine designs.
How CAD/CAMSystems Handle Indexing Work

Beforediscussing CAD/CAM system applications, is importantto establishsome it work. core understanding how CNCmachines of Priorto the inventionof CAD/CAM systems,G-Codeneededto be generated"by job, the only just like any other programming hand."Indexingwork was handled differencebeing that another one or two axes were sometimesadded to the mix. Most machinecontrollershave the ability to work in multiple local coordinate systems,also known as nestingpositions.These localcoordinatesystemswere, and still are, usedin a varietyof ways,One of the simplest ways is to placemultiple fixtures and parts on the machine,establishthe part data for each individualpaft, 4-15. and assignindividual localcoordinate systems, shownin Figure as
t z
Figure 4-75 Positioning two fixtures with parts on a machine and assigning individual local coordinate systems. The aboveexampleshows only two positions. The part programswould be the same would be provided for both, except that the local coordinatesystem designation at the beginningof the NC program (for example,G54 or G55 Fanuc).Different for controllersuse different designations these nesting positions,but they all work on numerousnesting positionscan be the same principle.Dependingon the controller, designated, This nestingconceptis one that many peoplestrugglewith, and its understanding is key to multiaxismachiningand programmingpractices. There are a variety of controllers and machinesavailablethat use this same concept,but they use different terminologyto describeit,
56
Machine Coordinate Systems

Machine Home Position Simplyput, Machine Home Position is the centerof the machine's universe. Everyaxiswill travelto its Home (end of travel)position and the machine will stop there.At this Home position, the machine's in Absolute Coordinate System, all axesare read ing/d isplaying zero. Everymovethe machine axesmakefrom here will be relative this zero. Everyposition to captured, suchas a nestingposition, position the Machine Coordinate System. Everytime a tool will be a relative in is changed, machine the position will go to the pre-determined specified this in MachineCoordinate System. To establish nestingpositions, first vise is loaded the the and checked make to sure it is squareand securebeforeit is clamped position. in Thenthe workpiece is placed the vise and the vise is tightened holdthe workpiece place.Using in to in an edgefinder, the centertop of the part is located, shownin Figure as 4-15. The position machine's absolute display shouldnow show how far the axesare from the Home position. This position must now be captured and the machine must be madeto remember this location. Machines remember storingthe relative by (from Home) in their registry. distances How nestingpositlons are'captured' depends the type of machine on and controller use. in Active Coordinate System positions a multiaxis Nesting on machine can be movedand rotatedin one plane. They can also be rotatedaboutthe machine's rotary/pivoting axes.
The Machine Home Position is the center of the machine's universe.
Indexing Multiaxis Toolpaths
57
Figure 4-76 Multiplenestingpositionson a tombstonefixture. positions, first of whichis shownin Therearetwo popular waysto use nesting the Figure 4-16, whichillustrates tombstone fixturein use.Everypart datumon the a Many tombstone fixtureshownhasits own localcoordinate systemassignment. programmers that the arrangement feel shownin Figure 4-16 is the bestway to positions. usenesting just one central Theotherway is to assign coordinate systemto the wholejob as shownin Figure 4-t7 .
58
t/
Figure 4-77 Central coordinate system on a tombstone fixture. Both methodsare correct and it is simply a matter of personalpreference to as whichone is used. When it comesto machininga singleworkpiece,a preferredmethod is to use only one Active Coordinate System method, but this also is just a matter of oreference,
Figure 4-78 Central coordinate system on a single part.

lndexing Multiaxis Toolpaths
Usinga singleActive Coordinate System requiresthat only one positionbe indicated the machine. This approach on simplifies process the and lessens the possibility error. of Machine Rotary Center Point So far it has been established that every machinehas its own Home Position, which is its center of the universe.Every localcoordinatesystem is a relative locationin that universe.Also, the intersection the rotary axis, commonly known of as the Machine Rotary Center Point, is a relativelocationin that same universe. and its positionis stored in the registry.
CAD/CAMSystem Origin
EveryCAD/CAM system 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 programmer to alignthe worldsof both the a CAD/CAM userand CNCmachine is machinesand the CAD/CAM systems. 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/CAM System'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, seenin Figure as 4-19.
Figure 4-79 TheRotaryZero Pointis wherethe two rotary centerlines intersect.
60
It on the otherhand,the multiple position nesting methodis preferred, new Active CoordinateSystems must be created the CAD/CAM in systemas shownin Figure 4-20.
Figure 4-2O The relationship of the part zero to the Machine Rotary Zero point.
SynchronizingMachine and CAD/CAMCoordinate Systems

TheseActive Coordinate Systems are the equivalentof the nesting positions (for exampleG54-59) on the machine.DifferentCAD/CAM systemsestablishactive coordinates difterentways. as shown in Fig. 4-2L. For the sake of simplicity, in the followingdescription will be kept very general. An Active Coordinate System can be established choosingan entity, such as a by solid face, an arc, two lines, normal to a surface,normal along a line, or normal to a ptane,
61
"p{
ffe
,
Figure 4-27 Multiple local coordinate systems. programming 3-axismachine one of the differences between a and a multiaxis machine the determination wherethe fixtureand part will be located the is of on m a c h i n ea b l e . t machlne, must be givenas to wherethe part On a multiaxis exact instructions shouldsit relative the Machine Rotary Zero Point. As always,a bit of preto planning go a long way.Avoiding will collisions between tools,tool-holders, fixtures, will be one of the major preoccupations. and machine components, example, for Creating accurate an libraryof the fixtureplates,vises,clamps,tools,and toolholders use in the plantwill help greatlyin avoiding in those potential collisions. in Findthe Machine Rotary Zero Point (described Chapter2) for every machine in in the shop,and placethe fixtureson thosevirtualmachines the CAD/CAIY to but at leastthe machine's system.It is not necessary modelthe wholemachine, Extracareshouldbe taken that all the modelssit ln this tableshouldbe modeled. (CAD/CAM machine). and aligneduniverse
Secrets 5-Axis[,4achining of
Figure 4-22
Complete Machine Simulation.
Depending the CAD/CAM on softwareselected,it is also possibleto model and simulatethe whole machinelike those shown in Fiqwes 4-22 and 4-23.
Figure 4-23
Virtual -axis horizontal machine for simulation purposes.
It is vitallyimportant that the "business end" of the machine modeled be accurately, any simulation to be useful,By the business if is end is meantthe head, fixture, table - in other words, the parts that can actuallycollide.Simulationwill be discussed more detail in a later chaDter. in
o4
SimultaneousMultiaxisToolpaths
f4anypeople think that simultaneous multiaxis the true form of 5-axismachining, is when in fact, it is not necessary all the machineaxes to move at the same time for for the machine be considered to s-axis.Evena simultaneous 2-axis,rotarycutting motionmay be considered be a multiaxis to toolDath. Simultaneous multiaxis machininq also knownas Continuous s-axisor is True 5-axismachining.
The illustration Figure5-1 showsa 2-axismachine in cuttinga patternonto a bowlingball.This machine only 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.
Figure 5-7 Set-up on a 2-axis machine for engraving a bowling ball. The examplein Figure5-2 alsoshowsa simplemultiaxis motion- so simplethat it can be programmed hand.The programcontains following by the codes:
65
c01 22.0000 F90. x - 5 . 5 A 2 8 8 0 . 0 0 0 F 5 0. GOO25.
Figure 5-2 A simple multiaxis set-up.
Figure 5-3 Sketch of simultaneous cutting on a 4-axis machine -XYZA,

Secretsof s-Axis l\ilachining
Figure 5-4 A 4-axis machine set-up for cutting a variable-pitch thread on an auger using motions on XYZ and A axes. Simultaneous cuttingon a 4-axismachine shownin Figure5-3, and a set-up is for cutting a variable-pitch thread on an auger using 4-axis motions XYZand A is shown in Figure 5-4. Figure 5-5 illustrates set-upon a similarmachine, a combining simultaneous motions,and using a flywheelto producea knee-jointcomponentusing the 4-axis motionsXYZ and C.
Figure 5-5 The4-axis simultaneous motionsXYZand C are showncutting a knee-joint, using a fly-cutter. Manypartswouldbe impossible machine to withoutsimultaneous multiaxis motion. In.theearlydaysof multiaxis machining, manypartsweredesigned around motion instead as freeform of CADmodels.
SimultaneousMultiaxisToolDaths
An exampleis the spiralbevelgear shownin Figure5-6, whichwould normallybe produced a special gear-cutting plant. on machine an automobile in
Figure 5-6
Spiral bevel gear produced on a s-axis CNCmachine.
Thisgearwas machined with the following manually-generated, motion-driven codes:

o0001_ c20 c 9 0 c 0 0 x - 3 . 7 5 Y 0 .2 2 5 . B - 3 5 . C 0. T l M O6 s300M3 s3000M03 c4323.5 H1 2 3. 2 5 G 1 z 2. 9 F 2 4 0. M98 P3000 L30 c90G00225.M05 M30 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
This last exampleis very simplistic, with somecreative but use of branching/looping logic.Someshopshave usedthis technique produce to very complexparts. There has always been a separationbetweendesignand manufacturing. Typically, paft designers are not CNCprogrammersor operators.As a result, many designs don'ttake account cleantool motion,or theV include of features that are hard to machine and requireadditional operations. well-runshops,designers In and production engineers work in conjunction, from the designprocess throughto manufacturing. This is an idealsolution, but unfortunately the norm. Working not in conjunction, engineers savemany hoursof valuable can manufacturing time, tooling, fixturedesignand building. CADsystemshaveevolved drastically and, as a result,it is possible designand to manufacture ever-more complexparts like the examples shownin Figure5-7.
Figure 5-7 Examplesof parts produced on multiaxis milling machines, including turbine blades and rotors, impellers, pump components, brackets, and manifold covers.
Simultaneous Multiaxis Toolpaths
69
Figure 5-7 Examples of parts produced on multiaxis milling machines, including turbine blades and rotors, impellers, pump components, brackets, and manifold covers. Developing cutting strategiesfor these multiaxis parts entails more than just creatingtoolpaths.The strategy is all about control.The goal is to create a toolpath that causesthe smoothest,most efficient,machinemotion insidethe machine's "sweet spot" (the optimum work envelope),while avoidingnear-misses and collisions betweenmachinetool components,fixtures and holders.
The Optimum Work Envelope

The optimum work envelopeis the spacein which the machine'srotary axes rotate The following an example. is aboutthe same diameters.
70
Figure 5-8 A vertical milling machine with a trunnion-type duat rotary tabte, set up to machine a model of a human head. Machining a modelof a human headon a trunnion-type of dual rotarytable is shown in Figure5-8. The head is high abovethe Machine Rotary Zero point, measuredalong the Z-axis, but it is very closeto the C-axiscenter point of the rotarytable, measured alongthe X and Y axes. In programmingsuch a job, it is best to avoid creatingsimultaneous rotary cutting motionsinvolving full rangeof the tilting B-rotaryaxis (-15 and +105 degrees) the while the C-axisis being rotated around its axis. Doing so will create uneven motions betweenthe rotarv mechanisms.
Figure 5-9 Example of part being placed far away from MRZP.
Simultaneous Multiaxis ToolDaths 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 circumferences widely differentfor the B and C motions. Highare quality machineshandlethese kinds of unevenrotary motions better than lowerquality machinesbecausethey synchronize two rotariesto arrive at the same the point, while maintaininga constantfeedrate.CAD/CAM systemscan also control feedratesby using Inverse Time Feedrate output. A more detailedoverviewof sectionof this chapter.At this point, it these controlsis includedin the Feedrates is sufficientto know that it will be much better to placethe workpiececloserto the machine. shownin Figure5-10, especially as of same rotarydiameters the specific qualitymultiaxis machine are in use. table,or a lesser if a third-party dual-rotary
Figure 5-7O The part is placed close to the Rotary Zero Point of the machine. Placing the workpiececloseto the same rotary diametersof any particular But machine, shownin Figure5-10, might not alwaysbe possible. when it is, as take advantageof this simple techniqueto better control motion.
Feedrates
On a 3-axis (non-rotary) machine,there is no need to specifya feedratemode these machinesall operatein the units/time mode. because as Forexample, you designate position G9L G1 x7 .07f07 Y7.07107 rl-0, if a your machineslideswill move the workpiecein a coordinatedlinear motion from destination x7.07107 Y7.07107 at 10 of its currentDosition an incremental to exactlv 10.000 inchesin a inchesa minute. The machinewill move the workDiece line. straight diagonal
72
Figure 5-77 A diagonal groove is machined by moving both tabte stides simultaneously using linear interpolation, With linear interpolation, the workpiecewon't get to 10 inches/perminute instantlybecause the slidesneed to accelerate from zero. Once a sDeedof 10 inches minuteis reached the machine capable), won,t instantly (if a is it stop at its destination.Instead,the slideswill decelerate that position,but for this to example, those losttimes are negligible. can calculate time of this 10.0000 We the inch movewith this equation:10 inches/minute = I minute.
Figure 5-72 Circular interpolation is used to move the workpiece in a circutar path.
SimultaneousMultiaxisToolDaths
A planarcirclecut usinga c3 r-5. F10. commandis illustrated Figure5-12. in The resulting motionappears be a true circle,but it is not. Any machine to that has the standard three XYZlinearaxescannotcut a true circle;only an approximate one.The slideson these machines can move only in straightlines.Therefore, in path,the controller haveto interpolate circular orderto generate circular a will a move by breaking the programmed circleinto a numberof straight-line segments. On most machines,the circulartolerancecan be set from insidethe control parameter settings. The largerthe sizeof straight-line segments, the lessaccurate the circles will be. A smaliernumberwill resultin more accurate circular cuts. Changing circular the tolerance affectsnot only the circular accuracy, alsothe but feedrate usedfor the cut. The machine will haveto slow down in orderto maintain the accuracy set, and the feedrate will changebasedon the sizeof the arc. Large arcs can be cut with a faster feedratethan small ones. Everyquadrant an arc includes peakerror area.whichconsists the points of a of where the linear axes intersectthe arc at 0, 90, 180, and 270 degrees.As the machineinterpolatesthe circle, it needsto reversethe slide motion of its linear axisto travelin the opposite direction. Evenif a high feedrate programmed, is the machine's controller will limit the executed feedratebasedon the circular tolerance set in the controller and the arc sizecurrentlybeingexecuted. this reason, For calculating cycletimes is not an exactscience. Multiaxismachineswork with two types of feedrates: . Standard (G94 units/time), described as above . Inverse Time feedrate(G93)
Inverse Time Feedrate Duringsimultaneous multiaxis rotarymotions,both rotaryand pivoting axes must ideallyarriveat a specified rotarydestination the sametime. Otherwise, at movementon one axis will stoDto wait for the other rotarv axis to arrive. This wait will causethe tool to dwell in one position, whichin turn, will change the cuttingpressure and deflection. the best casescenario, In this delaywill cause an unwantedtool mark on the part surface.In the worst case scenario,the pause can evengougethe part. CAMsystemshandlethis problemby linearization, which breaksup these movesinto smallersegments and applies controlled Inverse Time feedratesto them. The feed/minuteis specifiedwhen the tool needsto move at a specifiedfeedrate to maintainthe necessary feed per tooth to cut the material consistently. move To the tool with that feedrate,the rotary center points need to move much faster in space,especially longertoolsversusshorteronesare beingused. if The exampleshownin Figures 5-13 and 5-14 has only one rotary motioncombined with X and Z linearmoves.
74 Secretsof 5-Axis l\ilachining
Figure 5-73 The start position for machining a complex parc.
Figure 5-74 Destination of motion from start point in Figure S-13.
Simultaneous Multiaxis Toolpaths
to in 5-13 and 5-14, it is possible observe Looking the two illustrations Figures at and imaginethe differencein travel distancesbetweenthe tool tip and the rotary feed/minute the tool tip, on the programmed centerpoint of the head.To maintain the center of the rotary spindlehead needsto move very quickly.This scenario in to on can be compared runners a track. Running the insidelaneof the track coverslessdistance than 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 destination X units per minute.Instead,it shouldbe told to movefrom start at motion,on all the to destination, X amountof time, in a smoothinterpolated in axes involved.On Fanuctype controls,G93 signifiesthe staft of the inversetime a at mode.Theremust be an F command the end of every line containing G1, G2 and G3 code.The Inverse Time mode will not affect rapid G0 moves, In Inverse Time Feedrate mode, an F signifiesthat the move betweenthe in shouldbe completed (1 dividedby the F currentposition and the destination if number)minutes.For example, the F numberis 2.0, the movewill be completed in half a minute. Inverse Time Feedrates were widely used in the early days of NC, but today many modern CNCcontrollersare capableof parsingstandardfeedratesinto (A Usually, an or inverse time and vice-versa. parseris a compiler interpreter). into algorithmis incorporated this featureand it can be inverse time smoothing parameter setting. in enabled, disabled, the controller's or
Post Processors
systemsgenerates-axis vector lines along 3D paths.The 3D paths CAD/CAM representthe tool motion as it followsthe pattern being cut. The vectors represent (IlK vectors) the tool follows the 3D (XYZ) as the individual tool axis directions pattern. Everyvector is represented a line of code, and during toolpath creation, by a resolutionof these vectors can be specified,either by definingthe minimum angulardifferences, the linear distancesbetweenvectors,This informationis or system,the language Depending the CAD/CAM on writtenin a genericlanguage. do tool controllers not speakor CLS,NCI,and others.Machine may be calledAPT, many different however they do understand thesegenericlanguages, understand languages and dialects. language, into a mach ine-readable codemust be translated The generic CAD/CAM will calculatethe axis A a processthat is called post processing. post processor The motions neededon a specificmachineto reproducethe CAMvector sequence. physical post processor machine's information aboutthe specific includes detailed and computingpropertiesthat allows it to generatethe requiredaccurateG-Code. of that are needed This code,in turn, will governthe axis movements the machine
76
to machinethe part. A different post processor will be neededfor every type of multiaxis machine the shoD. in Postprocessors have built-in intelligence designedto detect rotary limits and automatically retract and repositionmachineaxes. Rotary moves are treated with a bias (not applyinga neutral point of view correctionto the process),basedon the layout, as well as the primary and secondaryrotary axes of the machine.post processors stay away, or warn of 5-axis instabilities, will and they can output rotary rapid motionsas programmedhigh feedratesto better control every aspectof a machine's motions. There are alwaystwo possiblesolutionswhen a post processor maps a s-axis tool orientationto a s-axis machinetool's kinematics. The post processors choose will the bestsolution the two. Consider example of the shownin Figure5-15. The currentposition xyz A+80.000 BO.0O0. theory.the tool couldalso is In reachthis same position xyz A-80.000 8180.000, but that would be at impracticalbecause the part would be hiddenfrom view and the oDeratorwould see the back side of the rotary device.Also, there is not enoughy-axis travel capability this specific on machine.
Figure 5-75 Oneof the two possible solutionsfor a S-axisposition. selecting bests-axisposition the taskof the postprocessor the is writer. Another task of a postwriteris to solves-axisinstabilities, knownas polesingularities. also These faultsoccurwhenthe tool is vertical almostvertical. or Mostoostswill generate retractmoves alongthe tool axisin thesesituations. Goodpostswill avoid erraticretractand largerepositioning moves tracking possible by the anglepairs, angle change limits, andmachine mechanical travellimits.
Simultaneous Multiaxis Tooloaths
lYanyCAMsystems handle safe motions betweentwo subsequent.toolpath Thesecontrols retract the tool into a safe operationswith post processors. from one operationto the next. area, and a s-axis machinerepositions safety volumes Instead of simply retractingto the MachineHome Position, (box, hemisphere, cylinder)can be used for efficienttool retraction.Keepin motions mind that an efficienttoolpath doesn't make erratic and unnecessary - it retractsthe workpieceonly to a minimum safe distance,and keepsthe axesin optimumpositions.. all while maintaining machine cutterengaged, developerhas dedicateddepartmentsdevotedto writing and EveryCAD/CAM and there are many consultantsmaking supportingtheir post processors, a living doing the same work. There is a great need for post processors can be becauseno two machinesor operatorsare the same' Postprocessors machines, alsoto suit the individual but not customized, only to suit individual If user's preferences. a companywishesto attempt to modify its own post processor, will providetraining and documentation. most developers lot of effort, for a Developing post processor multiaxismachinestakes a "hackers" who are There are many and perseverance. talent, professionalism, post processor supplied with is to managing "make it work,"but a high-quality switches. and user-defined detaileddocumentation writer visits corporatemachinebuildersto get An exceptionalpost processor on informationdirectly,and then developsand tests the post processor all the is machinetypes in use, The post processor thus tried, tested, and certified companyand the machinetool builder. by both the CAD/CAM
78
Common SimultaneousMultiaxis Toolpath Controls

A good CAD/CAM system is one of the most importanttools in a modern machine drive any multiaxis CNC shop,and will provideenoughcontrolto confidently are: equipment. The three major thingsthat needto be controlled
the Cut Pattern - Thispatternguides tool'scuttlngdirections. of Tool Axis Control - The orientation the tool'scenteraxisin 3D space it follows cut pattern. as the to that the tool tip is compensated Tool Tip Control - Thegeometry follow.
In additionto those three major controls,which are definedin more detail in this good-quality nce. collision-avoida systemsalso provide additional chapter, CAD/CAN4 Different avoidance This insurance recognize tool'scutteLshank,and holder. will the comesinto proximitywith when any of thesecomponents behaviors be invoked can 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 (for example,box, cylinder, Cut and sphere.) or 3D wireframe, solidprimitives or grids. Patterns can also be complexmulti-surface 6-1 through6-17 are shownin Figures Someexamples cut patterns of
79
Figure 6-7 Tool motion following a 3D curve projected on to the face of a workpiece.
Figure 6-2 Tool motion following the rib's bottom edge.
Figure 6-3 A Cut Pattern is selected to slice the part in any given plane, for example, patterns 3 or 4.
Figure 6-4 Impeller floor surfaces that use a Cut Pattern that morphs between the two blade surfaces.
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,
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\4ultiaxis ToolpathControls
'l
Figure 5-72 Path following a spherical Cut Pattern.
Figure 6-73 Path following a box-shaped Cut Pattern.
Figure 6-74 Axial Cut Pattern on a turbine blade.
Figure 6-75 Radial Cut Pattern 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 SimultaneousMultiaxisToolDath Controls
Figure 6-77 Cut Pattern following the natural flow of the surface - the grid lines.
Tool Axis Control

The examplesshown in Figures6-1 through 6-17 were designedto illustrate the results producedby tool motions on variousparts. It is necessary control to the directionof the tool axis as the tool followsthe Cut Pattern. The Tool Axis Control allows orientationof the tool's center axis to be manipulatedas it follows the Cut Pattern. The sketchesin Figures6-18 through 5-25 illustratethese conceDts
Figure 6-78 The Tool Axis can be locked normal to a plane. In this example, the Tool Axis will be maintained normal to the bottom floor surface of each individual inseft Docket,
Figure 6-79 The Tool Axiscan be lockedso that it always intersects any definedDointon the holderside.
Figure 6-20 The Tool Axis can be Iocked so that it is always aligned with a defined point at any distance as it follows the Cut Pattern.
Figure 6-27 The Tool Axis can be forced to remain normal to one sur-faceor to multiDle surfaces.
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 5-25 A Tool Axis can be forced to rotate about anv other axis. Figure 6-24 Lines can be drawn that will guide the Tool Axis as it follows a Cut Pattern.
In additionto the previouslydescribed Tool Axis Control Methods, more controls are availablethat allow the tool to be rotated around its tip by specifyinglead, lag, and sidetilt angles, shownin Figures as 6-26 through6-30.
Figure 6-26 Tool axis normal to a surface.
Figure 5-27 Tool axis at a lead angle.
Figure 6-28 Tool axis at a lag angle.
Figure 6-29 Tool with side-tilt angle.
Newersystemseven allowdynamicchanges be madeto the side tilt, or the to lead/lag angles, whilecutting.The examplein Figure 6-30 showsturbineblade machining whichthe Tool Axis is dynamically in controlled. With this control,the tool can be providedwith optimum accessto all the featureson the blade in all staoesof the cut.
Figure 6-30 Dynamic side-tilt angle changes.
Tool Tip Control

In summarywhenCAD/CAM systems creates-axistoolpaths, they will: . Firstgenerate numberof tool positions chosen cut Pattern a alongthe user's in as shown Fioure 6-31.
90
Secrets s-Axisl\4achining of
Figure 6-37 Generating tool positions on the cut pattern. The systemsthen assigntool vectorsto every one of those positions,basedon the Tool Axis Control method chosenby the usen as shown in Fiqure6-32.
Figure 6-32 The generated tool axis vectors. Next, they will move the tool to a desireddepth along the ToolAxis, basedon the Tip Compensation method.
CommonSimultaneousMultiaxisToolDath Controls
generated controla toolpathfor the humanheadshownin Forexample,surfaces to Figu 6-33. re
Figure 6-33 Human head sculpted under computer numerical control. The surfaceswere generatedby a scanner, and thereforethey are not the best quality. The file may havegonethrougha few translations. modelmay have The initially who saved beenscanned and savedas an IGESfile, then sent to someone it as a STEP file. Next,it couldhavegoneto anothershopwhereit was saved again as an IGESfile. Everytime a file gets translatedbetweendifferentCAD/CAM systemsthere is a toleranceissue.It is very easy for errors to be compoundedand produce poor qualityCADmodel.The modelmay consist thousands surfaces a of of if and there may be gapsbetween them. The Tool Axis wouldflip radically it tried to stay normalto all the surfaces it traveled. as Fixing the gapswould be very time-consuming. good,cleanmodelwill alwaysproduce nicerCut Pattern, A a cuts. stabletool axis orientatlon, and cleaner
A handy5-axistrick is to createa cleancore underthe poorqualitysurfaces. This clean core is used to generateboth the Cut Pattern and the Tool Axis is Control. Then,compensation applied the tool tip in cuttingthe outerto skin surfaces. followino the cleanoattern.
92
Secretsof s-Axis l\y'achining
Figure 6-34 A clean core was created under the poor-quality surfaces and the tool was moved to positions at the set depth.
Figure 6-35 The clean core was used to generate the Cut pattern.
CollisionControl
It is a giventhat collisions gougesare always be avoided, why is collision or to so control needed? Why aren't all CAD/CAN4 Systemsdesignedto avoid them automaticallv? That first sentenceabove is not alwaystrue. In some instances, there is a need to gougethe drivesurface! Whenwouldthis application useful? be Engine headporting is a good example.The shapesof the intake and exhaust ports are very complex. Traditionally theseshapes were carvedby hand,with carvingtoolssimilar to the instrumentsused by dentists. Reproducing these complexshapeshas always beena challenoe.
CommonSimultaneous Multiaxis Tooloath Controls
shapesand comes in handy for this The CNCprocessis very good at reproducing shapesinto the CAD/ The challengeis getting these hand-carved application. CAMsystem. Probingis a common method usedto reproduceports, A probe is a sphericalinstrumentthat is used to touch the part and record a point in space, Touching many pointswill recordwhat is knownas a pointcloudwhichis a group the part's shape.If a probe of the same diameter of pointsthat roughly represents 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
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 necessary transform the point clouds into workablesurfaces.Thesesurfaces to would exist relativeto the center of the probe and, in this situation,it would be necessary lead the tool center on the surface,(the same place where the probe to 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, Most engine builderstoday use either a more sophisticated scanningmethod that compensates automatically the probe diameter,or laserscanners/as shown in for Figure6-39, that read the exact shapesof the ports,
Common Simultaneous Multiaxis Toolpath Controls
vc
Figure 6-39 This probe sutface was generated with a laser scanner that can represent the true shape of the port, Collision avoidance must be usedwhen cuttingthesecomplexsurfaces. Collision control permits monitoringof the cutter'sengagementwith the sudace, while ensuring that noneof the other features the tool (shank,holdeqetc.) come in of contactwith any surfaces.Better CAMsystemsallow a choiceof ways to avoid collisions, and even permit "near-miss"distancesto be set for different parts of the tool, The impeller exampleshownin Figure5-40 has twistedand warpedblades, whichwouldbe impossible cut with the side of a tool. TheseshaDes to needto be generatedby steppingdown on each individualbladewith a ball-nosecutter.The bottomfillet is smallcompared the bladeheight,and although long and skinny to a ball nose cutter is needed,it is not practical. tapered-shankball-nosecutter is A preferred,Because there is very little room betweenthe blades,there is great dangerof gouging, both the bladebeingcut, and the neighboring blade.Caution is also neededat the hub surfaceto ensurethat it doesn't qet violated bv the nose of the cutter.
96
Secrets s-Axisl\rachining of
Figure 6-40 A warped impeller. strategies Some CAD/CAM systems providecontrol by allowingmultipleavoidance to be specifiedin the same path. For instance,in the aboveexampleit is possible to: . . . . . . o Specifycutting with multiple, spiralingcuts. Specifythat cuts should start from the top and work down toward the bottom of eachblade. Specifyuse of a tapered-shankball-nosecutter. Specify sidetilt anglethat is to be maintained. the 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. If the tool nosecomes in contact with (or within a near-missdistance)of the hub surface,it is instructedto retract along the tool's axis. If the tool holder comes within a near-missdistancefrom the toD surfacesof the blades,the machineis stoppedso that the tool can be moved out from the holder(longertool is needed).
This level of control allowscreationof a clean,smooth cut with a rigid taperedshankball-nose cutter,as shownin Figure6-41.
TooloathControls Common Simultaneousl\ilultiaxis
Figure 6-47 A Clean Cut Pattern with dynamic tool axis control. Not all CAD/CAM systems providethis amount of control. Some will only allow the definitionof check surfacesto be avoided,but will not orovidethe meansto avoid them. Keepin mind that thesecontrols focuson collisions between tools.holders, fixturing,and work-pieces. They will not avoidpotential collisions the machine. on To avoid collisions betweenmachinecomponents,like rotary headsor tables. machine simulation needed. is That subiectwill be covered the next chaoter. in
Additional Multiaxis Issues and Controls

Dovetail Effect
Even4-axis,and especially s-axis,motionwill introduce some uniquechallenges. Forexample,if a straighttool is plungedinto the centerline of a cylinder and then the cylinderis rotated, a dovetailshapewill be left betweenthe start and end positionsof the tool, as shown in Figure6-42.
EOVETAIL
Figure 6-42
The dovetail effect.
If the intentionis to cut a spline with parallelwalls, the tool should be moved off center,as illustratedin Figure6-43.
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.
Common Simultaneous Multiaxis ToolDath 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 conventional climbing,but this is not true or part. when cuttinga multiaxis
Figure 6-44 lllustration of Lead Lag in milling operations. the Whentakinga light cut, simplychanging the lead/lag angleof the tool changes cutting directionat the tool contact point, as illustratedin Figure6-44. The tool engagement areaalsochanges drastically deepor heavycuts, suchas in thoseusingleadand lag cut engagement shownin Figures 6-45 and 6-46.
100
Figure 6-45 Lead cut engagement in milling.
Figure 6-46 Lag cut engagement in millino. The examplesin Figures6-45 and 6-46 show differentengagements during the samecut, but changing the leadangleto a lag angle.The tool contactarea changesfrom the side to the bottom of the tool, Extra attention must be paid to this aspect,especially inserted,hollow-center, if non-bottomcutting tools are in use. Multiaxis Roughing There are many instances where it is necessary use long tools for roughing,as to 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, the side-loadincreases, As these tools will deflect,causingvibration, chatter,poor surfacefinish, and drasticallyshorter tool life. Multiaxisplunge roughingis a good way to remove material in these circumsrances.
101
Figure 6-47 Plunge roughing Plungecuts should not be made to the final depth all at once. Instead, it is best to plungeonly to a manageable depth, 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. systems also have the ability to look at the shapeof the stock Some CAD/CAM model and eliminateall air-cutsfrom the toolpath.This ability,combinedwith plungeroughing, roughing operations. can shaveoff hoursfrom high-volume multiaxiscut and therefore is a more rigid Plungeroughing is not a simultaneous 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 highre temDeratu environments.
102 Secrets s-AxisMachining of
MachineSimulation
Machine simulationis the safestand most cost-effective way to prove out multiaxis toolpaths. Usinga multiaxis machine proveout programs time-consuming to is and dangerous, both for the machine programs and for the operator! Running blindly on a real machine,basedon a wireframebackplotin a CAD/CAM system, is just as oangerous. programmers WhenCAD/CAM converse about programming multiaxis a machine, they typically use a special sign language involving rotatingarms and torsos,while holding two fingersand a thumb, signifying right-hand up the coordinate system in all kindsof different orientations. They visualize part and the machine it the as performs imaginary an choreography. visualization not easyto do, especially This is if there are many different machinetypes in the shop, Wireframebackplotsportray the tool motion as it moves around a stationarypart. This movementis later post-processed into machinemotion and is differentfor every different type of machine. The CD included with this bookcontains numberof a examples showing the same part beingcut on variousmachines. will be clearthat it eventhoughthe CAD/CAM backplot motionsare the same,the machine motionsare comDletelv different. With machine simulation, machine's a virtualreplica can be shownon the comDuter screenwhere the cutting processcan be simulatedsafely.This try-out will ensure that the programcontainsthe most effectivecut, the part is locatedin the "sweet spot". and no fixtures, tools, machine's or any machinecomponents will meet unexpectedly. It must not be assumed that machine simulation only to be usedfor prove-outs is with the soleaim of findingerrorsin the code.Instead,it must be lookedat as an additionaltool to help make clean,efficient,and accurateprogramsevery time. With simulation,differentapproaches and differentcutting strategiescan be tested on different machines, without leavingthe desk. And there is no need to tie down a machine prove-outs. for Nobody likesto see an expensive s-axismachine sittingidle whileprograms are beingtested, People make mistakes underpressure. Evensmallmistakes multiaxis on equipment proportions.Damageto the part, machine,downcan quickly add up to catastrophic time for repairs, repaircosts,and penalties reallyruin a business. can Running
103
is 5-axisprogramblindlyon a machine, Iike playingRussian a newrunproven/ gun chambers CNCequipment a as fully loaded. Usingmultiaxis roulettewith the than using verification systemdoesn'tmake sense,and is much more expensive for But simulation. with that said,nothingcan substitute the real thing, Evenafter the The sights,the sounds, simulation tests,the first run will alwaysbe exciting. but used is Machine simulation not a magicbullet, feel of the cuts are irreplaceable. properly,it is an extremely helpfultool. Old School Samulation Manv shopsstill cut foam or wax for prove-outs.Some will even replacethe part to and run the programon a finished cuttingtool with a flexiblepipecleaner, rapid They will slow down, overrideboth the see if there are any interferences. collisions. and keepa closeeye on all possible movements and the feedrates, program, either in If there are any closecallsthey will stop, makechanges the process. a complexpart, this On and manually in a CAD/CAM, repeatthe or machine, this process multiaxis state-of-the-art, can take days.On a complex, process prove-out of couldcostthousands dollarsin downtimealone.Only a should attempt this type of prove-out,even operator/programmer highly-qualified if it costs more in wages. Realities edit many peoplestill manually in capability, Evenwith today'sadvances CAD/CAM the code created by their CAMsystem.There are various reasonsfor this and some include the followinq: of those reasons Post processors are not configured properly' For example,during rotary again positioning and moves,the rotary brakesshouldbe disengaged, engaged is by duringcutting.This brakeapplication governed M codesthat vary with is different machines.If the post processor not configuredproperly,these M manually. codeswill needto be inserted A repeating pattern on the part can be called up, using subroutines. For example, an impeller has repeatingfeatures.Instead of letting the CAD/ CAMwrite long extensivecode, it is sometimeseasierto take the CAM-created code for one feature and repeat it using subroutinelogic.This procedureis particularlyuseful when there is a lack of memory in the machine'scontroller. No matterwhat the reasonis for usingthis method,you will find that this more efficientprogram is alwayseasierto prove out. Manually-programmed probing routines are introduced' For example, probing routine using system or user-defined variables a branching/looping tool changes. or at might checkthe part for alignment the beginning, between Then, basedon the results,the probing routine would adjust the NC code to alignwith the part. programmerstend to do more G-codeediting than new programmers, Experienced New programmerstend to embraceand trust the technologymore, and many are CAM in As with G-code languages. was established earlierchapters, unfamiliar
104 Secretsof s-Axis l\.4achining
systemsfirst generategenericintermediatecode (APl NCI, CLS)and then post process that code into the machines'specific G-codelanguage. NC machines All understand G-code, and when they readthat code,they translate into machine it motions.Everyword in that code, regardless where it comesfrom - the CAM of systemor manualediting- will be recognized withoutdiscrimination. most The commonquestion whetherto simulate is the intermediate codeor the G-code.
G-code Simulation Versus CAM Simulation

Onlya handfulof CAMsystemshaveintegrated machine simulation. Mostof those only simulate postedtoolpath code (XYZABC), the postedG-code.Some have not post processors that will post two streamsof code at once - a simplifiedone for simulation and the controlling G-code the machine. these post processors for If are configured correctly, virtual machine the and the real one will behave exactlvthe same. Thereis currently only one machine programthat can run simulation software true G-code and that is Vericut@ CGTech. by This programhas multiplemachine controllers available, and can be configured realistically to simulate known all G-code languages, including looping/branch logic,probingroutines, ing and G and lY codes.If configuredproperly,the program'svirtual machineswill behaveexactly like the real ones.Notethat both methods will only work if they are properly config ured. If the shopis programming manually, doesmassive or editsto the postedcode, it will needsimulation that is properly configured simulatereal G-code. the to On other hand, if the CAMt post processoris properlyconfiguredto drive an on-board simulation, other simulation needed. no is In eitherinstance, question ask is "Who will do this configuration?,, the to Configuring multiaxis machine simulation requires intimateknowledge each an of machine, simulation the software, and the post processor.
ConfiguringVirtual MachinesFor Simulation

Softwarecompanieshave teams of dedicatedprofessionals who spendall their time testing and applyingthe software. EveryCAMdeveloperhas a post department whichwritestranslators (post processors) every machines'language. for The department constantly is monitoring new developments the mach in ine-bu ilding industryand is in closecontactwith the machine builder's applications teams. Togetherthe teams developfactory-approved post processors. Without the efforts of the post writers, all CAMsoftwarewould be useless. The ultimate end Droduct of CAMsoftwareis not creatinggreat toolpathson a computer screen,but creating codethat will govern the movementson specificCNCmachines.
Machine Simulation
105
is simulation the goal,Vericutby CGTech, the best is If true G-codemachine handshas hundreds yearsof combined of because their apDlications team solution type of CNCmachine, and is capable configuring of any on G-code experience processing, specializes reverse-post in cells.The company even entiremachining just it to machine movements, and convert meaning that they start with G-code would. like a machine's CNCcontroller interfaces. offer multiplemachine simulation SomeCAMsoftwarepackages popular choiceis Machsim with Vericut. Another A few havedirectinterfaces in Moduleworks team specializes post The by Moduleworks. equally-capable produce processors and the G-code output. to both the simulation configured training and simulationsoftwarecompanyprovidespost processing EveryCAlvl a few days long. building. Thesecourses typically are and/orvirtualmachine to or can Companies opt to sendemployees one of thosecourses just leavethe work to the professionals. configuration building. of stepsin virtualmachine The following an overview the general is
Virtual MachineBuilding
the including chip conveyor, It is not necessary virtuallybuildan entiremachine to a process makesfor slicksimulation, coolant tank, and so on. Such NC controller, the but the only crucialpart that needsto exactlyresemble real machineis the the Thesemotionsmust exactlyreplicate real area nearthe workingenvelope. involved virtually to will coverthe process machine. The remainder this chapter of in 2. major machines that were covered Chapter The stepsare very buildall the software beingused. regardless the simulation of similar, The Skeleton The skeleton, kinematic or of The first step is to buildthe skeleton the machine. how the machine's linearand rotary/pivoting of describes structure the machine, Everymachine will havea BASE,TOOL, and STOCK axesare connected. component.The best way to see the skeletonof the machineis to stand by the naked,withoutthe covers. the machine machine and jog everyaxis.Try to imagine 7-1. the Observe examplein Figure
Everymachinewill have a BASE,TOOL, and STOCKcomponent.
106
C ",tor,,-.
a z _ MoDELS E
BEBrrrooels
TOOL
eY_^ {JMODELS
a x__
I+IMODELS
tA-LTJMODELS
sTocK_
BMoDELS Figure 7-7 Kinematic component tree.
The baseof the machine Figure7-1 is hidden, allowa betterview of the in to "business-end" the machine, of The kinematiccomponenttree (shownto the left in Figure 7-1) describes machine (shownto the right in Figure7-1). The BASE the is the first component.The Z-linear axis is attachedto the BASE, The B-rotary axis is connected Z. The indentationsignifiesthe axis priority,meaningthat if you to move the Z-axis, the B-axis will move with it, becauseit is carried by the same slide.The last componenton this branchis the TOOL. carriedby, or attachedto, the B-axis. 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-down skeletonof the machine.There are no modelsattachedto this skeleton,but you can tell by a glancewhich bonesare connectedtogether. Manyother component typescan be attached this basicstructureincluding, to fixture, tool changer,pallet changer,and robots. Components vs Models
Depending whichsimulation on software in use, multiplemodelscan be attached is to every one of the main components. This ability to attach modelsenables
107
MachineSimulation
different propertiesto be assignedto each of the models.Uniquetolerancevalues, visibility,and reflectivitycan be assignedto each model, colors,translucency, or on modelscan also be included excluded the collision-detection and individual settings. Most machinesimulationsoftware uses STL modelsas a default,and some can also use solid primitives(block, cylinder,cone, sphere,or torus). Other softwarecan use its native solid models,or a mixture of all the above models. in 7-2 through7-10. are illustrated Figures examples Somepopularmachine
.'
BASE
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Figure 7-2 Horizontal 4-axis machining center, shown in Figure7-2 is The horizontal4-axis machiningcenter configuration re very popularfor high-volumetom bstone-fixtu type manufacturing,Note the pallet changer,which can be adaptedto servicean entire pallet center.With this capability,multiple differentjobs can be introducedinto the manufacturingprocess the machine. withoutstopping
108
ar BASE
3Y
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Figure 7-3 Vertical 3-axis machine, converted to s-axis with a third-party dual rotary device. The modifications shownin Figure7-3 can be adapted sult most 3-axisvertical to machiningcenters.The dual rotary device bolts to the machine's table, instantly transforming into a 5-axismachine. it Some room will be lost in the Z-axisworkinq envelope, the multiaxis but capability be gained. will
Machine Simulation
109
ar BASE
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Figure 7-4 Verticat s-axis machine with a dual, rotary, nutating table' The machinein Figure7-4 is a dedicateds-axis Table/Table vertical machining ."nt"r- f,lot" the rigid machinebase. Such a machinecan handle heavy work with dence' and confi Drecision
110
of Secrets s-AxisMachining
.'
BASE
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Figure 7-S Vertical s-axis machine with a trunnion-type dual rotary table. Trunnion-type dual rotary configurations, shown in Figure7-5, are very popular in as the industry.This may be because they are competitivelypricedand easy to set up and ooerate,
MachineSimulation'l'l'l
.'
BASE *Y 3x
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Figure 7-6 Vertical s-axis machine with a dedicateddual rotary table. Figure showsanother 7-6 example a sturdy,dual-rotary, of s-axisvertical machining center. Thismachine hasthe ability spinthe C-axis a spindle, also to as allowing turning for workto be done.
'l'12
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Figure 7-7 Horizontal/vertical s-axis Head/Table machining center. The machinein Figure7-7 is calledVH - Verticaland Horizontal.It is a s-axis Head/Table machine,and its design allowsfor exceptional flexibility in additionto formidablerigidity.
lvlachineSimulation113
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Figure 7-8 Vertical s-axis Head/Table machining center. The vertical S-axis,Head/Table machinein Figure7-8 providesan amazing combination speedand precision. of
114
Secretsof s-Axis Machinino
.'
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Figurc 7-9 Vertical s-axis profiler, with a dual rotary head. Many manufacturers offer variationson the type of Head/Head configuration shown in Figurc7-9, commonlyknown as a profiler.Typicallythese machineshave limited rotary range combinedwith long bed travel.
Machine Simulation 115
'BASE
3x
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a sroc
Figure 7-7O Vertical s-axis laser machine, with a dual rotary head. The verticals-axis machine shownin Figure7-10 is usedfor laser-machining, but this kind of Head/Head configuration also very popularfor milling and water-jet is machining.
Machine Simulation Interfaces

A GUI (GraphicalUser Interface), or form of text file, can be used to build virtual machines.With such a program, models,or whole componentbranches,can individually. example, be manipulated For the virtualmachine can be usedto translate,rotate, or set dependencies, translucencies, reflectivity. or Oncethe virtualmachine built,all its axescan be movedindividually is with MDI (ManualData Input) commands,or slider bars, to check if the correct modelsare assigned the correct axes. Thesecommandscan also be used to check if the to positiveand negativemotions are correct. Remember that all simulationsoftware is uselessif it is not emulatingthe movementsof the real machine.The models representing the real machinemust be accuratein relationto the businessend of the machine. This area is nearthe work envelope and includes spindle, the fixturing, and rotary devices. Oncethe physicalmodel of the machineis built, the virtual controllermust be configured.In a CAMsystem this work is done with the post processor. Vericut, In configuration achievedwith a reversepost processor. is This configurationprocess is criticalin emulatino the behavior the real machines. of
Using MachineSimulation
Thesedays, very few peopleprogram exclusivelyby hand. Most peopleuse a CAD/ CAlvl system to generatecode.The palt is typicallyeither designedor imported, and then toolpaths are generated usingtoolsfrom an internalor an external library. Machine simulation can be run at any time duringor at the end of this process, provided the groundwork has beenlaid down and the machines havebeen b uilt. The process settingup machine of simulation very similarto settingup a real is machine. The part must be placed the machine the correctorientation on in and then the Local Coordinate System needsto be set relativeto the Machine Rotary Zero Position. The tools then need to be loadedinto the magazineand the Tool Length Offsets must be set correctly.This work can be time-consuming if there is no direct interfacebetweenthe CAD/CAM and the simulationprograms. If there is a well-configured interface,or if the simulationis an intricate part of the CAD/CAM, then settingup will take only a few seconds processing of time. NativeCAD/CAM simulationloadstools from its libraries.Vericutuses its own tool managerf it will builda tool libraryautomatically it is integrated or if with a CAM system.Oncethe part, tools,and toolpaths are loaded, the simulation ready is to be run, eitheras singleblocks, continuously. simulation or The can be slowed down or sped,and the modelcan be dynamically rotated.Somesystemsallow movementsforward or backwardat any time, but others don't offer this option. Somesystemswill show materialremovalwith simulation, and somewill permit analysis and measurement the virtualpart. Mostsystemswill signalif there is a of near-miss collision or between any configured components. They will also display an alarm if the limit switches are hit by over-travelling any of the motionaxes. on Operators ableto see throughmodelsby makingthem invisible, are whichallows examination the cuttingprocess waysthat are not possible a real machine. of in on Thereare many benefits machine to simulation, whichallowsdifferent ideasto be tested out without pressure.Estimatedprogram cycletimes can be accessed, to helpdetermine the bestone. Crashing machine the computer a on screenis not a big concern, whereas crashing real one is a catastrophe. not usinga multiaxis a But machine its full Dotential a shame.Simulation to is allowsthe best ideasfrom different cutting strategies,and the most efficientmotion for any specificmachine to be combined.
The processof setting up machinesimulationis very similar to setting up a real machine. The part must be placed the machine the correct on in orientationand then the Local Coordinate System needsto be set relative to the Machine Rotary Zero Position.
l\ilachine Simulation
't17
SelectingThe Right Machine For Your Application

Making multiaxis a equipment choicedecision similarto choosing car make is a and model.The decision needsto be basedon the intended use, budget,and \\garage" personality, alongwith many other considerations. multiaxis The includes the equivalents racecars,all-terrain of vehicles, buses,and luxuryvehicles. There are general-purpose machines and there are machines madefor specific applications. This chapter may help narrow the searchbasedon the specificparts being manufactured. Mostsmallshopsenterthe multiaxis arenaby addinga single-or dual-rotary unit to their existing 3-axisverticalmachining center. The addition the single-or dualof rotary unit allows pafts to be manufacturedmore quickly and makes it possibleto machine more complexpartsthat were previously of reach.Thisadvance out may causea chain reaction.When shops get better at producingcomplexparts, they start to chargemore for those parts. They then seek out even more challenging work to make more money.In turn, these ventureswill stretch the limits of capabilityof the prompting equipment, consideration purchasing of more new equipment. The available budgetis alwaysthe big consideration. priceof any machine The will reflect its quality, but as with cars, the price may also be affectedby the name brand. However,budgetaryconsiderations outsidethe scopeof this book. are Machine manufacturers spenda great deal of time developing machines. They also spendtime on their salesand marketingefforts. Reputable manufacturers have applications teamswho installnew equipment, train new customers, and provide ongoing technical suppoft.They alsoemploydedicated applications specialists who can preparebenchmarks, turnkey solutions,for prospects or and customers. Regardless the specificmachinetype under consideration, is smart to research of it the reputationearned by the support servicesprovidedby different manufacturers. MostCNCequipment sold by a dealernetwork.Not all dealers is will maintain the same quality of service.It is wise to visit local shopsthat have different CNCequipment and talk to them abouttheir experiences. them how their Ask equipment performing, is what the service like when there is a problem, is and if provided goodtraining.It may also be wiseto ask if the suppliers the manufacturer delivered all their Dromises. on
119
tr
manufacturer that suitsthe applications criteria, and then take a Selecta machine good look at the variety of pafts currently being manufactured your plant. Also in the in consider partsyou intendto manufacture the future.Consider following the scena rios. How many parts are typically run after each set-up? If your shop produces 500,000of the same parts per year,it would be wiseto look machineor machinesto producethat part. Investigatethe possibility for a dedicated may include a from the machine builder. Sucha solution of a turnkeysolution with multitasking machines and roboticloaders. complete machining cell,possibly Does your shop/company thrive on challenging jobs and have a reputation for producing complex work? Some shoos like to take on work that others considerto be too difficult.These companieslearn from every challengeand becomebetter and better with every job. Takingon difficultjobs may be risky, but it can pay great dividends.Before jobs, ensurethat your multiaxis is equipment contracting suchdemanding for precise, enoughfor the challenge. flexible, and adaptable 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/ need to be CAMsystem capability,and programmers'andoperators'proficiencies programmers waitingfor free machines, is againa good idea it If are scrutinized. Couldthe cutting strategy be improved? to checkthe CAD/CAM system'scapability. Imaginerunningold style high-speed steeltools on Are the right tools beingused? 1500 IPM - the limitations of capable 40,000 RPM of and a modernCNCmachine machine. the In hold backa very capable and very expensive cheaptoolingcould system is obsolete,you won't be able to use your CNC same way, if your CAD/CAM potential. equipment its full to Are you happy with the performance of your CAD/CAM system, and are you using it to its full potential? with their trainingon your Makesure that your CNCprogrammers up-to-date are potential.It is much cheaper CAD/CAM system to ensure it is being used to its full and easierto get organized,trained, becomeefficient,and promote teamwork, than and put it into production. it is to buy a brandnew machine Is your shop/company dedicated to a single manufacturing field, for instance automotive, aerospace, mold & die, medical or oil? field you are workingin will alsoaffectyour choice machine of The manufacturing type. There are differenttorque, speed,and precisionrequirementsin every field.
120
Secrets s-Axis of Machining
New Possibilities After determining that your shop is runningfull out and needsadditional equipment, is time to consider it new possibilities. first obvious The consideration the physical is sizeof the machine, and that is dictatedsimply by the sizeof the partsthat will be machined and the sizeof your shopfloor. The next consideration the material is that will be used,whichwiil determine the rigidityneeded. The qualityrequirements the machine of will 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,
Head/Head Machines (with long X- or Y-axis linear travel, but limited rotary axis travel)
The manufacture airplane panelsis a goodfit for Head/ of wingsand fuselage Head machines. The panelsare designed strength,but are kept as light as for possible. pocketing Thereare several tapered-wall machines that are perfectly suitedfor swarf-type toolpaths. Typically thesepartsare madefrom solidbilletst n two set-ups, shownin FigureB-1. as
Figure 8-7 A vertical mill set-up for machining an aerospacepanel.

Selecting The RightMachineFor YourApplication '12'l
An airplane wing stringeris a goodexampleof a part that is long,but very slim. Partslike this are typically machinedfrom specialextrusions,which can be over parts likethesewere madeon machines similarto the ones 40 feet long.Typically, fixturing. shownin Figures 8-2 and 8-3, usingmultipleset-ups and elaborate
Figure 8-2 Gantry-type Head/Head machine.
Figure 8-3 Bridge-type Head/Head machine. The Dartswould tend to deform betweenset-ups becausematerialwould be removedunevenly,first from one side, then from the other, in a secondsetup,The machine shownin Figure8-4 solves this problem.
Figure 8-4 Dedicated extrusion milling machine. The machine Figure in 8-4 is well suitedfor machining long extrusions. is a It s-axis machinewith X, U, Y, Z and A-axes.The U-axismoves parallelwith the X-axisand it has two sets of rotary jaws that are usedto clamp and traversethe extrusionpast the cutting tool. Cutting takes place in a narrow but rigid corridor in successive sections,The overall lengthsof the parts are limited only by the support systems eitherside of the machine. at
Head/Table Machines (with long X-axis travel)

Long parts, similar to the examplesshown in Figure8-5, requiresevererotary motions in the primary axis and limited rotary motions in the secondarvaxis.
Figure 8-5 Typicalrotary parts.

Selecting The RightMachineForYourApplication
123
These Dartswould be best manufacturedon the Head/Table machine shown in Figure8-6. configuration
Figure 8-6 Head/Table type milling machine' The rotary pivotingconfigurationshown in Figure8-6 is very suitablefor manufacturinglong rotary parts. The weight of the part is supportedby a tail stock, and the part is rotated around its center of mass. Ineftia is an important for the machines' Consider configuration when usingmultiaxis consideration in porting shown in Figure8-7, and imaginethe differences machine engine head movementswhen comparedwith Figure8-8.
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Figure 8-7 Head/Table engine head-port milling.
Figure 8-8 Dedicated Table/Table port milling dual rotary attachment.
SelectingThe Right MachineFor YourApplication
125
The machinepicturedin Figure8-7 is designedto rotate the head around its center of mass without generatingunwantedcenfrifugalforces' The machinein Figure8-8 "nock-and-Roll" dual-rotarydevice.It is designedespecially nas sometningcitted a on for machining-ports engine heads.The entire fixture holdingthe part is rocked thioughout thelutting processto presentthe work to the cutter.These una |.ori"a to fixtures need to be carefullybalanced ensuresmooth motion'
Head/Table Machines
8-9, 8-10' and 8-11' are suchas thoseshownin Figures Head/Table configurations This urnon6tn" most virsatile choicesfor a variety of other multiaxisapplications. removedand the ""rr"t]f ii'l"ri"es from the fact that the steady rest can easily be spa."canbeusedformountingadditiona|fiXtures.CustomizedfiXturescana|sobe jobs. built to suit special
Figures 8'9.and 8-7O Additionat versatility using multiple fixtures'
Figure 8-77 Machining an auger feed spira! for an injection molding machine'
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oi Secrets s-AxisMachining
Figure 8-72 Machining a rotary windmill unit.
Figure 8-73 An impeller. Figures8-12 and 8-13 representexamplesof veftical machineswith long X-axis are travels,but Head/Table machines built in many forms and shapes.
For Selecting The RightMachine YourAppllcation
127
Rotary Table- Tilting Head Combinations

Theexample shownin Figure 8-14 blursthe linesomewhat between vertical the and horizontal nitions. defi
Figure 8-74 This Head/Table machine is available in both vertical and horizontal configurations, The rotary-tableand tilting-headconfigurations shown in Figures8-15 through 8-18 are not suitablefor long parts, but can readily be adaptedfor a variety of multiaxis applications.
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Figures 8-75 and 8-76 Head/Table aerospacetand Head/Table automotive applications.
Figures 8-77 and 8-78 Two Nutating Head/Table configurations.

SelectingThe Right Machine For YourApplication 129
All rotary-table,tilting-headmachinestend to rotate the workpieces around their centersof mass while maintainingthe capabilityto reachall their featuresby tilting the head.Thesemachines built in many sizesand are widelyusedin many are different industries,from manufacturing small medicalparts (Figure8-19) where precisionand speedare the main requirements. manufacturing to large earthparts (Figure movingequipment 8-20), whererigidityand horsepower the are focus.
Figures 8-79 and 8-2O Typical medical part, and heavy equipment component manufacturing. In the mold and die industry, most of the roughing operations done on 3-axis, are verticalor horizontal machining centers. this manufacturing In field,one of the challenges cuttingdeep cavities tall cores, is or The deep cavities are designed with steepsidewalls,usuallyat anglesof 1 or 2 degrees, and often requireuneven floors with small fillets along the intersection the wall and floor surfaces,as of shownin Figure 8-21. Cuttingthesefilletson a 3-axismachine would requirelong, ball-nosecutters. Small steps need to be taken, causinglong cycletimes. The tool is often deflectedby the high cutting forces,causingvibration, excessive cutter weaq and poorsurface finish.
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Figure 8-27 Typical plastics-mold cavity. Usinga s-axis machineallowstapered ball-nosecutters to be used for this work. The taperedconfigurationmakes the ball-nosetool much more rigid for the same diameter,and the ability to tilt the tool also allows use of a shorter cuttet as shown in Figure8-22. More aggressive cuts can then be taken, shorteningthe cycletime. Deflection the rigid tool is less, and vibration is eliminateddue to the reduced of deflection. Tool life is increased, and a precise.good-qualitysurfacefinish is achieved.
Figure 8-22 Multiaxis machining allows for the use of shorter, tapered cutters,
Selecting The RightMachine YourApplication For 131
Table/Table Machines
of Figures8-23 and 8-24 show the most commonconfigurations Table/Table table and to are machines, The partsto be machined clamped a dual-rotary The dual-rotarytable is are rotated around the tool, Inertia is a consideration. either mounted on the machinetable or is a dedicateddual-rotarycomponentof the machine.These machinesare not suited for manufacturinglong parts' The when some tool changerlimitationsare work envelopeis fairly limited, especially is considered, Despitethe limitations,this configuration very popular.
Figure 8-23 A populartrunniontype setup.
Figure 8-24 A dual rotary "rock and roll" fixture.

Table-mounted units are not completelyrigid, but dedicateddual rotariescan be both agile and rigid. They are equally well suited for 3+2 indexingwork, and for simultaneous multiaxiswork. Some applications are shown in Figures8-25 through 8-28.
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.
SelectingThe Right MachineFor YourApplication
I,5J
Gantry Type Head/Head Machines

cantry type Head/Head machines,as shown in Figure8-29, arc used for large permits parts, mostly in the aerospace, and wood industries, This configuration oil, of are to long lineartravels.Some machines designed allowchanges heads in additionto tools. Rigidityand precisionmay not be the strong suit of these machines,but long reach capabilityis.
Figure 8-29
Water-jet/milling combination machine.
Some more machinevariationsare shown in Figures8-30 through 8-33. However' that are to it is impossible describeall the different machineconfigurations available,especiallybecausethis is a constantlyevolvingfield.
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Figure 8-3O A s-axis laser cuttinq machine.
Figure 8-37 This machine presentsa good compromise between lonq reach and rioiditv.
SelectingThe Right MachineFor YourApptication
135
Figures 8-32 and 8-33 A 6-axisindustrialrobot, and a 7-axisindustrialrobot. Thischapter only covered mostpopular has the designs, somesuggested and spend on It that applications based experience. is recommended engineers whenchoosing machine, a research only of the not sometime on initialresearch machine, alsothe intended but use.
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Choosinga CAD/CAMSystem For Your Application

Choosing the appropriateCAD/CAM system is as important, if not more important, than choosing most suitable the multiaxis machine. Thereare many specialized machinesthat are dedicatedto specifictypes of work, howeverone CAD/CAM system will driveall the CNCequipment the shoD. in 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. CAD (ComputerAided Design)/CAM (ComputerAided Manufacturing) always is referredto as one combinedsystem becausemost CAD/CAM systemsoffer both designand manufacturing capabilities. aware, however,that very few excel in Be both CADand CAM. Systemswith heavy CAD emphasishave their roots in CAD and are better at solid modelingso that they can handle large assemblies with ease.Thesesystems have associativity betweenall 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. Systemswith heavy CAMemphasisare good at everythingrelatedto toolpath creation, from simple2D drilling, contouring, and pocketing multi-surface to and multiaxis machining. Toolpaths be generated all kindsof CNCequipment can for includingwire- and other- EDM,water-jets, lasers,lathes, mills, and multitasking machines. These systemshave intelligenttool librarieswith associated feeds and speedsfor different materialsand cutter types. Instead of heavy CADcapability, these systemsare very good at importing CADdata from any system, with the main goal of generatinga toolpath from that data.
Special Purpose Software

Many specialized CAD/CAM systems have been designedfor specificpurposes.For example,some shops in the mold and die industry use CAMsvstemsthat have virtually no CADcapability,but they can import large, complex,multisurface files quickly.The user only needsto choosethe tools and selectfrom a short list of
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posted, cuttingstrategies. toolpathis soongenerated, A and readyautomated when engineering changes to-go.The trade-offfor this speedand easeis realized are necessary, Those changesneed to be made on a separateCAD system and imported back into the CAMsoftware.Also, these specialized CAIYsystemswill (lathe,EDM,plasma, waterjet,etc,) not suppoftany other kind of CNCmachines Thistype and many won't even supportsimplecontour, drill, or pocketroutines. purpose CAMsoftware only makessensefor shopsthat are machining of special to a largemold cavities day in and day out. It may be necessary purchase separate programming CAl4. seat of CAD,and maybeeven anotherseat of generalpurpose Softwarethat can dynamicallychangethe feedratethroughoutthe cutting process Thisfeaturemimicsan is anothergood example a specialized of CAMfeature. feedrates standing the machine at and overriding programmed the by operator manipulating feedrate override dial. In mold and die manufacturing, manually the largeamountsof materialneedto be removed. The topography multisurface of moldsis often so complexthat it is impossible maintain constant to a step-over, or the even a constant depth of cut. Cuttingforceson the tool vary greatlythroughout process machining of largemoldsand dies,and the work can take hours,days,and every to and anticipate evenweeks.It would be impossible standby the machine feedrates,but with feedrate motion of the axes, and overridethe corresponding This takes optimization, software the will vary the rate automatically. optimization place before any cutting is done, basedon constantsfor volume removal rate, chipload, surfacespeed, and other factors. Feedrate optimizationproducesconstant and cutting forcesthat are designedto lengthentool life, increaseaccuracy, shoftencycletime. dramatically Softwarethat is specifically designedto generatetoolpathsfor lathes is one more and CAD/CAM. Thissoftware offerslimitedCADcapability exampleof specialized only turning-specific toolpaths.The softwareis often built in to the controllers on certainmachines, and only generates toolpaths specific that machine's to language.With this type of softwarethere is no need for a post conversational processor. The approachis very direct, and that can be an advantage.Howevet it to can also be a disadvantage because thesetoolpaths cannotbe transferred any plasmacutters,and other specialized Grinders, lasers, water-jets, other machines. machines can all operatein this samefashion. that can closethe loop In addition CAD/CAM to systems, othertoolsare available packages can help check designand manufacturing. Simulation software between the resultsgenerated CAMsoftware, by and are a very importantlink and optimize worlds.Ensuring are bulletproof between the virtualand physical that toolpaths in the virtualworld will savethe shoptime and moneyin the long run. Thesetools work. shouldnot be overlooked when the shoo is beinooutfittedfor multiaxis
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CAD/CAM Toolbox
Buyinga CAD/CAN4 system is like buying a fully stockedtoolbox, but care must be takento ensurethat it contains the right toolsfor the job. All tradesmen have their own ideaof the perfectset of tools.A perfect of sharp,high-quality set chisels wouldbe useless an electrician. the sametime, it would be cumbersome to At to usea SwissArmy knifeas a screwdriver day long. all Very few CAD/CAM systems can do everythingwell. They all have their strengths and weaknesses. the other hand,very few companies On needall the power affordedto them by a modern CAD/CAM softwaresystem.The trick is findinq the right bala nce. Some CAD/CAM companiesprovidefor the capabilities their softwareto be of increased the companygrowsand demands as more functionaiitv. Mostfirst time CAD/CAI4 userswill start off with softwarethat can perform only simple 2D drilling, contouring,and pocketingtoolpaths.Oncethe users becomeproficient,they can take on more complex, 3D, multi-surface machining, multiaxis or 3+2 indexing work. Fromthat point,userscan move into complex, simultaneous, multiaxis milling,or evenoperation multi-tasking of milling/turning machines.
Multiaxis CAD/CAMConsiderations
Multiaxismanufacturingrequiressoftwarethat is very strong in CAlv.CAD capabllity needed, is but mostlyto import CADfilesfrom all the major CAD systems, all the popularCADdata formats.On top of that requirement, in additional CADcapability needed createsuppofting is geometry tool axis to for control, fixturedesign, virtualmachine or building. High-end CAD/CAM systemsare fully associative. a designchangeis made,the If change will propagate throughthe entiredatabase and will modifythe necessary movements the toolpath. in This featureis helpfulif one software package used is for the entiredesig process. a single,all-encom n-to-ma nufacturing passing If packageis not used, then extra cost is being incurredfor associativity that cannot be used. Unfortunately, most geometry associativity only works with native geometry. Most multiaxisshops import files from a variety of customers.Thesefiles could havebeendesigned any numberof CADsystems, it is crucial be able to in so to readand write in multiple CAD/CAM languages. Oncethe modelis imported, it is critical havegoodanalysis to toolsto analyze and then separate major it its features into organized layersor levels. After the modelhas beenanalyzed and organized, geometry someadditional creation may be needed. This geometrycouldinclude additional wireframe, edge curves,lines,arcs,points,non-trimming surfaces, evensomesolidmodel or creation. This work will requirelight-duty CADcapability.
Choosinga CAD/CAMSystem For YourApplication
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Multiaxis CAM
The categoryof 3+2 indexingwork requiresthe ability to quicklyand easilychange to the work planes,which are alwaysperpendicular the spindle/toolaxis. The planes,also known as Active Coordinate of creationand manipulation these work Systems, should be intuitive and easy-to-use'Some systemswork interactively by allowingthe user to simply pick a solid face, an arc, two lines,three points, and such. to definethe orientationof a new Active Coordinate System. This selection is a light-duty capabilityfor most CAMsoftware. multiaxis Heavy-dutyCAMcapabilityis neededfor tacklingsimultaneous This capabilityhas to be a delicatebalancebetweencontrol,flexibility, applications. and ease of use, A shotgun approachdoesn't work well here - the precisionof a rifle is needed. consider mold and die work as an example.This work is one of the most demandingand accuratefields in manufacturing.Moldscannot be mass-produced features,either a but are made one or two at a time, and they have predictable good 3-axis roughingstrategy will always core, or a cavity,or a little of both. A analyzethe work well here. Some CAMsystemscan quickly and automatically generatea toolpath to machinethem' In this featuresand then automatically shotgun approach,a wide field of targets can be coveredwith one shot. Precise control is neededwhen it comes to driving simultaneousmultiaxis The followingis a list of must-havetools from a well-rounded,multiaxis, machines. CAMsoftwaretoolbox. Pleaserefer to Chapter6 for detailedexamples. Cut Pattern Control It is important to have a variety of ways to define and control the pattern that will be followed by the cutting tool. These patterns can be anythingfrom a simple wireframeto complexsurfacepatternssuch as that shown in Figure 9-1.
Figure 9-7 Spiraling cut pattern on a turbine blade.

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Tool Axis Control Toolaxis control providesthe ability to set and manipulatethe center axis alignment the tool duringthe cuttingprocess, illustrated Figure9-2. of as in Thesecontrolscan be dynamic or static, but it is essentialthat they work in a predictable, stable way.
Figure 9-2 Positions of tool axis controlled by lines. Tool Tip Control The tool tip control targets the precisearea of the tool tip's engagementwith the part, as shownin Figure9-3.
Figure 9-3 Tool tip compensated to follow the outer surfaces of the work.
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Collision Avoidance Measures betweenmoving components/ Care must be taken to avoid potentialcollisions and betweenmoving and stationarymachinepads when multiaxistoolpaths are being generated,As illustratedin Figure9-4, this particularcontrol focuses particularlybetweenthe cutter,arbor, holder,and on meansto avoid collisions, fixture assembly. the workDiece
Figure 9-4 Dynamic shank collision avoidance. Stock Recognition Roughing Strategies in 9-5, will savetime. Illustrated Figure duringroughing Stockrecognition trims the toolpath to the stock size.This stock can be stock recognition materialcreated by previousmilling the initial CAD data or the in-process affair and this feature operations.Multiaxisroughingcan be a time-consuming is a must-havein creatingefficientroughingtoolpaths.
roughing,usingstock recognition. Figure 9-5 Plunge
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Machine Simulation Machine simulation eliminates guesswork the and the needto prove-out new machiningprocesses real machines,Usinga real machineto prove-outa on toolpath wastesvaluableproductiontime and risks potentialcollisions. Userfriendly and powerfulvirtual machinesimulations,as shown in Figure9-6, can improve productivitytremendously, but care must be taken to configurethem properlyfor each machine.Pleaserefer to Chapter7 for detailedexamples.
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 parts can be cut only in the CAD/CAM software. Without post processing, 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 specific postsare language. Customized multiaxis usuallyan extra charge,It is importantto find out if they are availablefor each specificmachineand how much they will cost. A professional post processor is usuallydeliveredwith supportingdocumentation that explainsits featuresand all the availableswitchesto activatethem. CAMsoftwaretypicallycomes with a set of genericpost processors, which are user-configurable. if postAsk development trainingis available.
Choosinga CAD/CAIVSystem For YourApplication
143
Multiaxis CAD/CAM Training

that machining, is not recommended it of Because the complexity multiaxis of multiaxisprogrammersbe self-taught.Trainingis a very important part of getting the most out of the softwarepurchase,and the best training is hands-on Trainingshould includeimportinggeometry,creating throughoutthe entire process. post processing, simulating thesetoolpaths a virtualmachine, on and toolpaths, Thesesteps representhalf the job. The next step is to learn how to set up a real machine,find the machine'sRotary zero Point, set the tool locations,load the toolpath into the machine'scontrollel and then cut the real part. Nothingcan with running a new programon a real replacethe feeling of excitementassociated machine. It is essentialto find out if this kind of programmingtraining is offered by the CAD/CAM companythat respondsto your requestto quote. Many programmers training take three- to five-day,cannedtraining courses,which use pre-arranged It sessions and step-by-stepinstructions. is possibleto completethese training the carefully laid-out steps,but there is no requirement courses simplyfollowing by for the user to retain any insight into why they are followingthose steps.These will get back to work and not know where to start. Very specific user/trainees questionsneed to be asked about the training optionsoffered. are very good, are alsoan option.Someof thesecourses On-line trainingcourses The appealof these offering narratedvideos, and hands-ontraining sessions. coursesis that users can take them at home at their convenience. CAD/CAM companiesalso offer on-site training,This arrangementensuresthat the focus is on the operationand the parts for which the programswill be used. The Caremust be takento stay on course dangerwith on-sitetrainingis interruptions. at all times. The chosen CAD/CAM companyshouldprovide What happens after training? support after training is complete.It is very helpfulto have that applications support availableas a safety net for at least the first few jobs. softwareis constantly How about update training?As mentionedearlier,CAD/CAM evolving,and it is important to keep up with these changesby attending periodic Userforumsare alsoa very goodway of keepingup with updatetrainingsessions. ideaswith peers. changes and a good way to exchange
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Behind the Scenes: CAD/CAMSoftware Development

The softwarethat is ultimately chosenwill have a profoundeffect on the business. Not only will the shopget the software functionality run its machines, will to it also be allying itself with a companythat can provideyears of experience and invaluable support.Considerable thoughtshouldbe givento the companybehind the software.A well-esta blished,reputable,companycan becomea valuableasset and partnerto the operation. Understanding developmentcycle of modern CAD/CAN4 the systemscan be helpful when softwarecompaniesare being researched. The followingbehind-the-scenes look at the development cyclewill illustrate why it is important selecta large, to well-esta blished companyas opposed a fly-by-night to business. CAD/CAM developmentis a very dynamic process.A successful CAD/CAM company consists many teamsof individuals of workingtowardthe samecommongoal.The individuals strive to make powerful,flexible,and user-friendlysoftwarefor the all end-user. This task is difficult becausethe more adaptiveand powerfulthe software is, the more complex it becomes.Complexityand ease-of-use often conflictwith each other,and writers of good softwarestrive to find a balancebetweenthe two. Imaginationis a very important and fundamentalpart of CAD/CAM development, but it can be tricky becauseit must be tempered with todayt (and tomorrow,s) hardwarelimitations.Theoreticalpossibilities always restrictedbV current are hardware limitations. CAD/CAM designis a long-term, ongoingproject, and hardwareadvancesmust be correctlyanticipatedand implementedinto the software. planning done by mixedgroupsof individuals Software development is who include software engineers, mechanical engineers, applications engineers, sales, people. and marketing Thesegroupsare also heavilyinfluenced feedback by from existing users. Existingusers help these groups make up the "wish list,,of new tools, as well as the recommended improvementsslotted for the next software release.The softwaredevelopers take a close look at the.'wish list.,and determine what can be done,when,and how. Oncethe softwaredevelopmentteam has producedthe first usableproduct, they will make it available the rest of their teams,including to qualitycontrol, applications, post development. thesegroupswill conduct and All their own usabilitytests and providefeedback.The developers will use this feedbackto fix bugs,improvethe interaction, and make performance enhancements. cvcleis This repeated continuously, until a stable,predictable, user-friendly Betaversion ofthe softwareis created. The Betaversionis distributed a special groupof end-users to who will conduct their own tests. At the same time, the softwaremanufacturer,s apDlications departmentwill conduct more tests by cutting real parts on real machines.
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process, everything carefully is documented. Throughout this development groupwritesHelpfiles,and trainingmanuals are The technical documentation and tested for each product. developed process, At the very end of this planning, development, testing,and documentation a new versionof the softwareis launchedand monitoredat every step. At that point,a dedicated with any technical supportteam is readyto assistcustomers issues that may a rise. groupkeeps process. But this point is not the end of the development The planning plans. on dreaming and makingnew The software development team staysbusy workingon those plans,and so on. A goodsoftware companyhas largeteams in of professionals orderto be ableto continually developnew and improved edge of software tools.The work is neverdone because is literally the leading it on technology.
General Guidelines for Researching CAD/CAM Software

the Start CAD/CAM research online.This approach can be a greatway to compare featuresand benefitsof severaldifferentsoftwarepackages.Many sites include demo video files, which can providea good feel for the software'sinterfaceand will often illustratethe software'snewestfeatures.The web site will also indicate of in details any localreseller your area. with whom the shopwill work are Conversations peersor with companies with usefulto learn what kind of softwarethey are using and why. Ask peopleif they easyor hardto learn?Can are happywith the localsupport,and was the software Werethere any hidden filesfrom outsidesources importedand exported be easily? costs?Is the local resellerreDutable? Wouldthev recommendthe softwarethev are ? using Visitsto tradeshows stronglyrecommended. are Tradeshow demonstrations are short and are gearedto show off the latest hot featuresof the software.Visiting to software companies tradeshows at also provides opportunity talk directly the to their corporatestaff, and the staff can includepeoplefrom all the different groups might responsible the software for development. Chances that the localreseller are also be on handto explainspecific features and services. Suchvisitsare a prime and opportunity learnwhetheryou would like workingwith the firm's employees, to to see if they are genuinely trying to helpyou or just trying to make a sale. packageshave very similar features,making lvlostof today's modern CAD/CAM it extremelydifficultto comparethem with each other.Another problem is that the packages are alwayssubject to development,and thereforeare constantly changing. Beware anyonewho makescomparisons of between competing CAD/ CAIYsystems,and bewareeven more of peoplewho are trying to make a sale by puttingothersdown.A tradeshow a great opportunity meet the peoplewho is to In develop and supportthe software. addition lookingat the latesthot features to
tr
of the software, take the time to assess you wouldbe workingwith if you the people decided purchase software. to the Are they enthusiastic abouttheir product? Are they behaving like a team, or are they shifty.disinterested unhelpful? and The following are among important questions that should be asked when visiting software companies: . Can you start smalland then increase functionality your business as grows?Many softwarecompaniesoffer different levelsof the software, Findout if you can buy only the functionality needtoday,and add to it you lateras the business develoos. Findout whereyour localreseller located, is and try to meet someone from the company. Ask questions regarding training,support,post processors/ and other aspects purchase. of Makesure you are comfortable with the reseller because supportyou receive the can make or breakyour softwareexDerience. How established the softwaremanufacturer? is a good idea to find a is It reputable company with a largeuser-base and supportnetwork.Findout how many programming seatsare usedworldwide. use of the particular Is softwareat which you are lookingtaught at trade schoolsor colleges? You may want to considerhow easy or difficult it may be to find employees that already know how to operateyour softwareof choice .
The next importantstep is to set up a demonstration your plant.The localsales at representative shouldvisit your shop,Iookat your operation, and basedon what kind of work you do, evaluate whetherthe software the right fit for you. If it is, he/ is she can also recommend propersoftware you the functionality need.Beware sales of representatives start with "Do I havea solution you!" even beforethey see who for the type of work you do.
Choosing CAD/CAM a SystemForYourApplication
Putting It AII Together

By now, readers shouldhavea good graspof the multiaxis process, machining with a clearunderstanding the different of types of machines, multiaxis toolpathtypesand machining techniques, multiaxis CAD/CA|Y controls, simula on options, and how they all fit together. test your new knowledge, to answerthe following To try questions. Answering questions the successfully meansthat you are readyto bre;k lnto the fast growingmultiaxismachining world. AIIquestions be answered subsequent will pages.and rneseanswers on can serveas a quickreference guidefor the most importantlessons learnedin this book.
QUrZ
1.) Name three benefits to using multiaxis machining techniques, 1.
2.) Describe a standard s-axis machine?
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3,) which of the following is the standard axis convention?
A 4.) what are the three major multiaxis machine types?

1. ') 3.
5.) what are the three major building blocks of a cNc machine? (Circlethree.) . Machine table servo drive system . SpindleRPMand horsepower . Physical propeftiesof the machine . Chipconveyor unit . CNCcontroller capabilities . CNCdrive system . Linear table limit switches
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i 6,) What are the most important physical positions of a multiaxis machine? . Centerof gravity, Home Base ProgramHome Base,IncrementalZero Position, Spindletype . MachineHome Position,MachineZero Position, ProgramZero Position
7.) What tools are needed to find the Machine Rotary Zero Position (MRZP)? (Circle two.) . . . . . level edgefinder dial indicator maintenance manual hammer
8.) Describe indexing/rotary positioning work,
9.) What is a post processor?
Puttinglt All Together
't5t
ANSWERS
1,) Why use multiaxis machining techniques? . . . partsmoreefficiently Multiaxis machining techniques usedto manufacture are and accurately eliminating by extraset-ups and fixturing. Standard shorter toolingcan be used,whichresults the abilityto rough in moreaggressively, whileincreasing life. tool A moreprecise surface finishcan be achieved avoiding by contact with the non-spinning deadcenterof the tool.
't52
Secrets +Axis Machining of
Figure 7O-7 Multiaxis machining manufacturesparts more efficiently, increases tool life, and producesa more precise surface finish,
2.) What is a standard S-axis machine? This is a trick question! Thereis no suchthing as a standard s-axismachine. Multiaxis machines available many shapes are in and forms. Figure10-2 shows examplesof the varioustypes of s-axis machines.
Figure 7O-2 Examples the varioustypes of of 5-axis machines.
Putting lt All Together
153
3.) What is the standard axis convention?
Figure lO-3
The standard axis convention,
The X, Y Z linear axes shown in Figure10-3, representing the Cartesiancoordinate system,move in straightlines,in plusand minusdirections. A, B, and C rotary The axes rotate about the X, Y and Z axes respectively. The U, V and W axes move in straight lines, parallelwith the X, Y and Z axes respectively. 4,) What are the three major multiaxis machine types?
TABLE/TABLE HEAD/TABLE HEAD/HEAD
154
Table/Table Multiaxis Machines
Figure 7O-4 Table/Tablemachines can be configured vertically or horizontally. Table/Table multiaxis machinescan be configuredverticallyor horizontally, as shown in Figure 10-4. The rotary motions are executedby the dual rotary table of the machine.The rotary table carriesanother rotary table, which in turn carriesthe fixture and the part. With these machinetypes, the part is physicallyrotated around the tool. The weight of the part and fixture need to be handledby the machine's rotary devices,so inertia will be a factor when considering fast movements. Head/Table Multiaxis Machines
Figure 7O-5 Head/Table machines are very capable and versatile.
Putting All Together lt
155
Head/Table machinesare arguablythe most capableof the three groups.They can machinelarge, heavy parts. On some Head/Table machines,the work piece is held by a rotarytable and is supported a tailstock, shownin Figure10-5. as by The work piece rotates around its own axis. The pivoting head only carriesthe generatedas it articulates weight of the tool and it handlesthe cutting pressures aroundthe work Diece. The rotary axis on these machinesusuallyhas unlimitedrotary motion, Some can even spin the rotary as a lathe would. The secondarypivotingaxis has an upper and lower rotary/pivotinglimit, Head/Head Multiaxis Machines
Figure 70-6 Head/Head machines can be both vertical and horizontal. On Head/Head machines, example whichus shownin Figure10-6, all an of rotary/pivotingmotions are executedby the head of the machine.Head/Head machinescan be both vertical and horizontal,where one axis has limited motion. Somecan changeheadsin addition tools.Heads to can be straight,90 degree, nutating, continuously articulating. addition milling,these machines In to can or also be outfitted to manipulatea water-jet or a laser. 5.) What are the three major building blocks of a CNC machine? 1. The physical properties of the machine The physicalpropertiesof the machineare representedby the machine'sskeleton. Everymachine built on a uniquebase.The qualityof the iron givesthe machine is its rigidity.The linear and rotary axes are stackedfirst onto the base,then onto give the machine eachother. The qualityof the linearslidesand rotarybearings
156
its flexibilityand potentialaccuracy. The spindlemotor'storque and horsepower further definethe characterof the physicalmachine. 2. The CNC drive system The CNCdrive system represents the muscles of the machine.The CNCdrive system consistsof componentsdesignedto move the machine'slinear and rotary axes. These componentsincludethe servo motors. drive system, and ball screws, which are responsible moving the machine'slinear and rotary componentsin a for smooth, preciserand rapid manner, 3. CNC controller capabilities The CNCcontroller the brain of the machine. is Data handling, available on-board memory size, and dynamic rotary synchronization controls,are some of the things controlledhere. 6.) What are the most important physical positions of a multiaxis machine? Machine Home Position - Most machinistsrecognize this positionas the placeto which all the axes move when the machineis initiallyturned on and Zero return is selected,as shown in Figure 10-7.
Figure 7O-7 Machine at Home Position.
Putting All Together lt
157
of Machine Rotary Zero Position - MachineZero Positionis the intersection the by rotary/pivotingaxes shown in Figure 10-8. This point may be unreachable the machine.
Figure 7O-8 Machine Rotary Zero Position. Program Zero Position - This position,shown in Figure10-9, is also the part datum locationin the CAMsvstem.
Figure 7O-9 ProgramZero Position.
158
7.) What tools are needed to find the Machine Rotary Zero position (MRzP)? The tools neededto find MRZPare a level and a dial indicator. 8,) Description of indexing/rotary positioning work
Most CAD/CAM systems let the user define multipleActive Coordinate Systems in space,and then create toolpathsusing the orientationof each individual coordinatesystem.As shown in Figure10-10, the Z-axesof these coordinate systemswill align with the spindle,signalingthe post processor output rotary to indexing commands into the NCcode.
Figure 7O-7O Multiple Active Coordinate Sysfe/.ns. 9,) What is a Post Processor? CAD/CAM systemsgenerates-axis vector lines along 3D paths.The 3D paths representthe tool motion as it followsthe cut pattern. The vectorsrepresentthe tool axis direction(IJK vectors) as the tool followsthe 3D (XyZ) pattern. Every vector represents line of code,This informationis written in a genericlanguage. a The genericCAD/CAM code must be translatedinto a machine-readable language. This processis called post processing. post processor A will calculatemotions neededon a specificmachineto reproducethe CAMvector model, which will govern the machine'smotions in order to cut the part. A different post processoris neededfor every type of multiaxismachine.
Putting All Together lt 159
1O.) Definition of an axis either Iinearand/or rotational Any motion controlledby the NC controller, an considered axis.
Figure to-t7 In this examplethe spindleheadand the quill move in the same z direction,but are controlledby two separatecommands, and W respectively. 11,) Defining a simultaneous S-axistoolpath must moveall 5 multiaxis toolpaths believe that simultaneous False. Mostpeople whilecutting,whenin fact a singlerotary tool continuously axesof the machine motion. multiaxis cutting to is combination considered be simultaneous andlinear Figures 10-12and 10-13. in are multiaxis toolpaths illustrated Typical simultaneous
Figures 70-72 and 7O-73 Examplesof simultaneous multiaxis toolpath motions'

12,) What are the three common simultaneous multiaxis CAM toolpath controls? 1. Cut Pattern - Guidesthe tool along cutting directions. 2. Tool Axis Control - Controlsthe orientationof the tool's center axis as it followsthe Cut Pattern. 3. Tool Tip Control - Controlsthe geometryto which the tool tip is compensateo. In additionto the abovethree major controls,quality CAD/CAM systemsalso offer additionalcollisioncontrol. Even near-misscollisionavoidance the cutter, shank, of and holder can be checkedagainst any part of the workpiece,fixture, or machine comDonents, Pleaserefer to Chapter6 for more detail.
More in Review: Multiaxis Machine Offsets
PIVOT
= TANCE
OFFSET COMP LENGTH'
Figure 70-74 In addition to Tool Length compensation,multiaxis machinesuse other offsetsincludingGageLengthand RotaryPivotDistance.TheRotaryTool plus GageLengthOffset. ControlPointDistance the sum of Pivot Distance is
Putting ltAll Together 161
Quick Reference:How to Find Machine Rotary Zero Position

For Table/Table Machines:
Figure 7O-75 Step 1: Level the A-axis.
Figure 1O-16 Step2: Findx,Y center.
Figure 70-77
Step 3: RotateA+90 and set dial indicator to Zero.
162
Figure 70-78
Step 4: RotateA-90. Dial indicator should read Zero
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: and orientation that vertical headis in a perfect First,makesurethat the machine true. is the spindle running
Figure 7O-2O Step 1: Use a dial indicatorto checkfor verticalalignment.
Figure 7O-27 Step2: Checkif spindleis runningtrue.
164
Figure 70-22 Step 3: Record Z max.
Figure 70-23
Step 4: Record Z min.
Z max Z min
GL - Gage Length R - Dowel pin radius = .5OOO Formula to calculate Pivot Distance: PD=Zmax-Zmin-GL+R
ltAll Putting Together 165
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.Indexing work is rigidand precise, is recommended all It that possibleroughingoperationsbe performedin this rigid state.
Figure 70-24
Indexing/rotary positioning work is the most basic multiaxis concepL
Picking a CAD/CAMSystem For Multiaxis Work

When selectinga CAD/CAM system for multiaxiswork, make sure it is CAM oriented,and has a powerfulCADtranslator. The CADtranslatoris very important becauseit's likely that files will be receivedfrom many different sources.Makesure pluscollision the CAMsystemhas all the multiaxis controls, checking. Havingan when project onboard,easy-to-use.machinesimulationis a big plus, especially planning. Machine work envelope are and machine component collision checking reou ired. In additionto the abovefeatures, it is also very important to researchthe CAD/ CAMsystem developerand the local dealer.Do they providequality training and support, and do they have post processors your machine? for Pleaserefer to ChaDter9 for more detail.
'166
Machine Simulation
Do not assumethat machine simulation usedonly for prove-outs is with the sole aim of findingerrorsin the code.Instead,machine simulation shouldbe regarded programs as an additional tool to help make clean,efficient, and accurate every time. Machinesimulationpermitstesting of differentapproaches, differentcutting strategieson different machines,without leavingthe desk. There is also no need to tie down a machine VourDrove-outs. for Machine iets you builda replica simulation virtualmachine the computer on screen,where cutting processes can safely be simulatedto make sure that the most effectivecut has been created,that the part is locatedin the machine's "sweetspot,"and that no fixtures,toolsor any machine components meeting are unexpectedly.
In Conclusion Congratulations the commitment become on to more informed aboutmultiaxis machining! Multiaxis machining a dynamic, is ntly-evolving consta field,full of possibilities. lYultiaxis machine toolswill becomemore complex and capable, and CAD/CAM systemswill develop additional capabilities controlthem. Userswill to continually look for more capability, combined with easeof use,and this demand will pressure machine the builders and CAD/CAlvl developers combine to their effoftsin building machine/controller combinations with built-inintelligence. As pasttrendsshow,thesedevelopments open yet more possibilities, will addingmore complexity. Creativity doesnot fit into a box, but knowing the basicconcepts allow will engineers think outside to the box. Hopefully this book has demystified this field and inspiredyou to take the next step in training yourselfto becomemore proficient and competitive with all the toolsavailable. The best measure of competencyin any field is mastery of the availabletools. Mere possession of more powerful tools doesn't make one more capable, but knowledge does. The manufacturing industryin general, and multiaxis machining padicular, ln is bestsuitedfor thosewho can think outside the box.Thereare alwaysmultiple ways to solve any problemand that solutionalwaysstarts with oneself.The biggest is secretof s-axismachining the realization that all the expensive CNCmachinery, CAD/CAM, simulation and software are meretools.Withoutthe knowledge use to them properly, nothingcan be accomplished. With the available toolsand the right yourself, your imagination knowledge, you haveto do is imagine- by applying all will become realitv. a
Puttinglt All Together
167
Index
A
ABC lineara{es.l5 coordinate system. 5? Absolute systems,25 2'7 57,59-61 140 Activecoordnrab , , Acturl part zeropoint, 27 Aligneduniversc,62 45 Avoiding collisions. 3 lool Automatic changing,16.42 Cuttnrg dircciion,l00 117,138. 167 strategies, 70. 103, 45. pitchthread, 67 variable
D
9, Dedicated multiaxis machnrcs. 10 machine and of Designations directions multiaxis Desired cutterarea. engaging,l0 Dovetail effecl. 98 Dynanic contol of tool axis,90,98 robry fixtureoffset.16.27-8,36
dcfined,l4 substitution,32
B
10,96,130 Bal]-nose cutters, l0 linishes. Bettersurface (3,7. CAD/CAMsystems, 27, capabilities.l39 coDsiderations, I 39 multiaxis origin,60 selecting,137 145 soft waredevelopmcnt, rcsearching,146 tmining,l4,l (PD),33,37-8, pivotdisiance 169 Calculating 139 CAM, multiaxis, 3 multiaxis machines, Can-operated heads, 53 spindle Changeable positioning repeatibjlity.'12 Checking Circular 73 interpolation, Clean core,92 CNC 3 controllers., 76 capabilities,l3,157 l3 drivesystems, (see collisioDs) avoidance Avoiding Collision 4, misconccptions,6. 7 Common of Complexity rvork,120 control, 92 3, nunerical Computer Crashirg,I I 7 94, Cutpattem,79,86 140,161
E
16 work envelope. Effectivc cutterarea, l0 Engaging desired 123 millingmachine. Extrusion
F
progritn,34 Fanuc Fcedrate, T2 138 dynanicchanges. inverse time,74 6 optimizaiion,l3S standard lime. 74 Finding the 21. ccnterofrotation. 27'8 l6l. l6,l pivotdistance, 36-9. 33, XYzero,23 5'axis nachineierms,13 vectorInres,76, 159 nachines,39 positioning,T
G
Gage (GL),36-9. length 161 tower,24,163 122,134 typehead/head machines, Ganrry G codes, 30.56, 104'106 29. 169
sinulntion. 105 G 90code.29.30 G-91 code.29.30 ll6 Gaphicaluscrnrtel1ace,
M
Machine 7.57 61.140, 15' aclivc coordirrte system.25 1,13 113 139. 4, 167 bxilding virtual,64, 6,116-7, cnd,6,l, 107. 125 busnrcss 1,10. 7,56-7.61'2. 159 coordinate systems,25 157 home posidon, 16,57.60.78. slstcns,25,26. 6l localcoordinate
H
nrultiaxis machines. 18.367. ll5 6. Head/head l2l 2. 13,t. 156, i64 bridgeiype. 122 ganlry1ype,122. 13,1 michnre, 116.135 lasercutting jer ll6. warcr miling machnre. 134 18,31.36. Headltablenrultiaxisnrachnrcs, 113,1 123,1.155 129, aerospace, automotive applications, 133 ports,125 hcad millingenginc nilling longrotarypafts.124 mdd anddic applications, 130 129 nuiating head conbinations, rotafylxble,rilthg head.12830 124 various conligurations, 9 with longX'axis tavel. 123 work,56 Ho\vCNCmachines Historyof 5 axismachining.3
I
I n d e x n r g , 2 l , 4 4 , 5 1 15 5 . , 33 lixtures,5l methods.5l toolpaths.49 wirh rotar)devices.52 wo*.:19.55 Indusrrial robots. 135 Interpolation circular,T3 linear,73 Inverse tnncleedrate, 72-4.76
L
Leadandlag jn milling.100 Lnnihlions,,16 Linear 166 .txis, 6,34.,19.74, 121, 14 106. 73 interpolation. Local coordinate systems.25 8.61 2,117 7.56
hone positior(MRHP),l7 zero point, 25-7, 60 2,1 1 2, 1M 21, 36. (MRZP).6 '7 ,25.21.36, position I zero ,21 6 1 1 7 , 1 5 8 ,r9 .2 165 103 simulrtion,27,63-4,98. 6. 143. 7 graphical userinlefaccs.I l6 using. tl7 Machirlnlg centcr conJigul"tion. I l0 108 complex worRpicccs,5 cngnrc components.20 profiling. ll5 progrrn,29 104. routines.5. 138 spnd bevelgears.68 Machsim softwxlc,106 Maintenance issues.40 (MDl),25.1l6 Manual inpur clrt.t Master system,60 coordinalc zero,26 M-code.2l,43,60 with nvc or moreaxes.4:l Milling nachines \ 4 o , r e l i n -r. ., ' 1 . u l . l l ' . I n - P l l 6 l 1 - - r ) 2 159 6. 124. Multiaxis machines.3 8, 17-9,40,7,1. 153 140 camtype.3. 110, l2l) dedicated,6. 21.39,52-3, 9 10. and l5 designilions directions. physical propeties, 156 13. 1402, 166 rorghing. 101. 21. 130, 58. Multiplenestnrg, 61
N
positioDs. 26,56 8, 61 25. Nesling Newpossibilities, 121 11. parts,120 Nunbersof
170
Secrets s-Axls of l\,4achining
Nunerical conlrol. 3
R
pxltcrns, Rcpcating l0,l Rotary andpivotingaxcs, 74 32. axis, 16,21,33.,12.60.71.7.1, i21, 156 107. d c v i c c1 , , 1 8 . 2 1 . 5 1l l 6 . 1 5 5 s6 2, xrdexing nechanisns, 54 5, mcchanisns.19,20.39.403. 52 3. 7l 6, tool cortrolpoint(RTCP).33'4.36. l6l Rotary tables,5. 18,21,27 8.9. 8.31 2. 130-2.
o
Old schoolsimulatifl. 104 One zero meihod,60 Optimum rvork envelope.70 Odgin,26,60
P
Pallet chargers, 54, 107-8 40, datum, 21.27,58,158 17, zeropoirt (PZP), 8 27 Plunge roughing, 101-2, 142 Probes probing,94-5, and 103',1 properties I'hysical of5-axismachines, 13 Pivot distance.33 point,37 9 Pivonng spindle heads, 18,32-6, 124.156.lbo 38. Pockct nrilling.5.86, ll7 9 l2l, $ork. 5, 7, 8. 13,20-l, 26. 42,49,52, Positioning
r 5 5 .r 6 3 6
brakes, 21,.10, l0,l 52. d e v i c e1 6 , 89 , 2 1 , 5 1 . 7 7 . 0 9 11 6 , 2 61 5 5 s. 1 2 1 . 1 . (RTDFO). dynxnicfixlurcoft.\cl 16,27 8.36 sinsle anddual. 8. 18.39.ll9 6, Roughnrg. 11,21, 101'2, 130, 140'2, 152, 166 Routnrcs,5.40,42, 5 104 S Second rotart table,18 Selecfirg nachnlcs, l9 I Selecting software. 137 Stullrlaftrn, 27,47. 4.98.10317.I38,166 19, 63 7 cutlingmotions, 10,71 milling te.hniques.2l muhiaxis toolpath conirols,79, 101,152. 161 toolpaths. 65.78. 103, 5.48. 105, 107. l2l Special-puryose lvare,137 soft heads. Spindle changeable. 53 31. Spil"l splines,99 Standard multiaxis nomenclature. 15 Slock(natcrial)option1.47. 102 rccognition,1,12 104 Subroutines.3.43. Surlace linishes. better,5,10 origin.60 view,27
r 5 9r,6 6
processing,3.4.8.34,40,76 8. 103-6, 138, 1 4 3 , 1 5 9r 6 6 , 7 processor,3,4, 8,39,40,76 10zl I16,138. 9. 6, 1 4 31 4 7 , 1 5 9 , Probing routines. 5 104 Program nnnurleditnrg. 104 subloutines. ,13 10.1 9, -4. (PZP). 8,25.32. zcro position l6 117. 158-9. 162 q 1 /. P r o g r d m n r i l g ...1 8 . 2 4 5 6 . 5 4 . 6 ) . l . l 0 : . 105.138,144.147 .onsiderations, 46 languages,3 limitrtions.46
and 46. Qucstbns answers, I 44. I 41. 119 physical positions, 151,157 standard convention. 154 axis 150.
T
Txblc/lxblc multiaxis machnrcs, 9.24.I10.125, l8 1 3 21 5 5 . 1 6 2 , wjth port-nillingaftachment, 125
'171
111, honnion rock andro11Iixtules,71. I32 and applications. 133 various 5 toolpaths, 3D surfacing heads, 31 Tiltingspindle Tombstone lixtures, 40, 58-9,108 6, Tool 139, axiscontrol,79,86,89,91-2,98,l4l, 161, 18 lengrh offsets, , 24, I 17 lists,46, 140,145 for lathes. 138 simultaneous,65 planewith odgin,27 79, tip control, 90-91,l4l Tradeshows,146 Training,144 2 + 3 positioning,49
U
XYZ andC,67 Usingmotions Unlockedrotary drives, 11 U\r!V linear axes,15
v
software, 1,95, 106,116-117 Vericut Verilication system,27, 104 1, companies, 146-7 Visitingsoftware 103,105 Virtualmachine, building,l06 107 components models, and 105 for configudng simulation, kinematiccomponenttlee, 107 106 skeleton,
w
wire franes,79,103,139-40 Worldzero,26,60
x
7,74 axes,15.32,66 XYZ linear
z
Zeroingthe indicator,22 162 position, 17,21, 117. 158, Zero Z-Maximum,37 Z-Minimum,38
172
lrachining secrclsof s-Axis
Virtual MachiningCD
were modeled usinglvlastercam@ Allthe imageson this CD, including virtualmachines, the (CNCSoftware, were broughtto life usingthe machine simulation Inc.). The virtualmachines (lYoduleworks)and VERICUT6 (CGTech). capabilitiesof l4achsim Installation drive. if the autoThe enclosedCD should run automaticallywhen inserted into a CD-ROlq run feature does not work. please use File I\4anager navigateto the CD. Find the file called to Index.html and dolrble-click it.
System Requirements
on The CD was built to run ootimallv a PCwith: . . . . . . Windows or Vista XP Internet Explorer(Version7) or higher (or 1024x 768 resolution higher) to installed. (Go to http://www.adobe.com/downloads/ install a Adobe@ Acrobat Reader@ free version,) plug-ininstalled. to hftp://www.apple.com/quicktime (Go to installa AppleQuickTime free version,) If you installthis cD on your hard disk.you will need650 l4Bfree space.
Virtual Machining CD Contents: . over 25 Interactive Machine simulations - self-extractingexecutablefiles launch interactivemachinesimulationsessions.Take control of all aspectsof the simulation, speed,and individual axis control.Lookat the including view manipulation, simulation machiningprocessfrom various views impossibleto see on a real machjne.This offers a a machining concepts, uniquevisualization helpunderstand varietyof multiaxis to . . Real Machining videos - watch a real s-axis machine pefform several different simulLaneous 5-axisparts, multiaxis cuttingroutines complex on virtual Machine Siniulation Videos - WatchVERICUT action;F it elecutesmachine in multiaxis examples complex of simulation and verification over a halfdozendifferent on parts. guidesfor the most important aspectsof setting Printable PDF Files - Quick Reference concepts available easyprint-outs, all as up a s-axismachine and commonmultiaxis found Image Gallery - See full colorexamples many of the partsand machines of throughout the book.
. .
Technical Questions: or to Please emailyour questions info@industrialpress,com the authorat to and go karlo.apro@gmail.com.visit www.5axissecrets.wordpress.com to the link for FAQS. Or

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Karlo Apro

ttn ril llillffill

Industrial Press, Inc. NewYork

Printed Thomson by Press IndiaLimited

Formore information the author,Dlease on visit www.multiaxissolutions.com

Chapter4r Indexing MultiaxisToolpaths . . . , .49

Chapter 5: SimultaneousMultiaxis Toolpaths. ,65

Chapter6: Commonsimultaneous Multiaxis cAM ,.....79 Toofpath ontrols C . C uP a t t e r n s . t

A d d i t i o n aL 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 M l D o v e t E f lf e c t . ai C u t t i n gi r e c t i o n D I v l u l t i aR os g h i n g . xi u ....,.......98 ..........100 ........101

R o t a r T a b l e T i l t i n gH e a d o m b i n a t i o n.s . . , . . . . 1 2 8 y C . . T a b l e / T a b v ea c h i n e s . . lli G a n t r y y p eH e a d / H e ald l a c h i n e s . . T v ..,....I32 .,.... L34

MultiaxiscAD/CAlvlConsiderations .,..... M u l t i a xC s f 4 . iA l 4 u l t i a xCs D / C AT4 a i n i n.g. , , i A I.

Behindthe Scenes:CAD/CAM SoftwareDevelopment . 145 . GeneralGuidelinesfor Researching CAD/CAM Software. . 146

Chapter 10: Putting ItAII Together, . , , . . . . .149

History of S-Axis Machines

Figures 7-7 Example inductionpump set-up of

Figures t-g and l-4

Examptesof positioning work.

I common Misconceptionr don't ilo enough S-axis work to warrant

Figure 7-7 Example of tombstone fixture.

Reasonsto Use Multiaxis Machines

Figure 7-9 Example part requiring positioning multiaxis machining.

Figurc 7-17 Dedicated dual-rotary machine set-up.

Figures 7-75, 7-76, and l-t7

More examples of parts that require simultaneous cutting motions.

Know Your Machine

Figure 2-7 Typical arrangements of multiaxis CNCmachines.

Multiaxis Machine Configurations

Figure 2-3 Machineat Home PositionX0. Y0. 20. A0. 80.

Table/Table Multiaxis Milling Machines

Figure 2-7 A third-partyrotary mechanismfastened the tabteof a standard to

usedin enginemanufacture. Figure 2-9 Specialized dual rotary mechanism

Machine Rotary Zero position (MRZp)

Finding the precise center of rotation is the foundation of accurate work.

Evensmalldiscrepancies magnifyerrors.furtherawayfrom this machine will rotary zero point.

Know Your Machine

Figure 2-19 Sketchshowingsomeofthe many localcoordinatesystemsusedin programming. CNC

Rotary Table Dynamic Fixture Offset

Secretsof s-Axis Machining

rey E-1grylo1selection E (oFFSET) --+

Activatino RTDFO: G54,2 Pn; G54,2 PO, n RTDFO- ON RTDFO- OFF

Fixture offset number (1-8)

The G-Code belowshowsan examDle:

Secrets s-Axis of Machining

Head/Table Multiaxis Milling Machines

Secretsof 5-Axis lvlachining

G49; G43.4 . . . x,l ,z, Toolcenter point function (Type 1) ON

G90G00G54x0, Y0.80. s5000M03

Know Your l\y'achine

Figure 2-34 Examplesof Head/Head machines.

Finding the Pivot Distance

Figure 2-38 4-axis horizontal machining center.

Know Your Machine

General Maintenanceand Issues for Multiaxis Machines

Figure 2-39 Example of rotary mechanismsplaced in offset positions by design.

Secretsof 5-Axis l\4achinino

Milling Machineswith Five or More Axes

Secretsof s-Axis Machining

Secrelsof 5 Axis Machining

Know Your Stock Options

Indexing Multiaxis Toolpaths

Figure 4-3 An aerospacecomponent machined with an indexing set up.

Figures 4-4 and 4-5 Two examples of custom-built, indexing fixtures.

Figures4-8 and 4-9 show some examplesof dedicatedmultiaxismachine,rotary mechanisms.

Secretsof s-Axis Machining