5-Axis Machining Demystified - Part One

MTB Tech Blog

5-Axis Machining Demystified - Part One
Tim Markoski: Posted on Tuesday, November 13, 2012 7:48 AM

As a general rule, 3-Axis CNC Programming and Machining is understood

fairly well conceptually. All tool motion is defined by positions in 3D
space represented by the Cartesian Coordinate System. The cutting tool
axis is generally always parallel to the Z-Axis or perpendicular to (normal
to) the XY Plane. Recent Posts
ObjectDialogue™ - A
Continuous 5-Axis Programming & Machining increases the level of File Open/Save
complexity as the cutting tool is no longer always perpendicular to Dialogue
(normal to) the XY Plane. 5-Axis has compound angular components that Replacement for
are represented by the angles of rotation about linear axes. Developers
SIEMENS 840D -
Continuous 5-Axis Machining has become more prolific with the advent of Creating Custom
powerful PC based CAM Systems. While CAM has made it much easier to Cycles
create 5-Axis tool paths, it has also created a problem in that it has SIEMENS 840D -
disconnected many from the underlying mathematics that are the basis Creating Custom M-
for all 5-Axis CNC Programming. We're about to change that. This article Codes
will be the first in a series dedicated to 5-Axis Machining. FANUC G43.5 RTCP
Type II - Vector
In order to better understand 5-Axis we need to expand our technical Programming for 5-
vocabulary a bit. The first term we need to understand is the word Axis
Vector. Simply put, a vector is an abstract entity that indicates a CAM Software
direction. In 3-Axis Machining we already know that the cutting tool axis Vendors and Post-
is always parallel to the Z-Axis or perpendicular to (normal to) the XY Processors
Plane. This direction is referred to as the Tool Vector. A Tool Vector is
Categories
always referenced with its start point at the tip of the tool along its
centerline. It is generally terminated with its end point at the tool gauge CNC Techniques
line - the intersection of the tool holder taper and the spindle taper. CNC Technology
Editorial
Our Tool Vector has as start point and an end point. These points have FANUC Settings
X,Y,Z coordinates and are, by definition, located in 3D space. These Management
locations are critical to the mathematics for 5-Axis. The distance SIEMENS Settings
between these two point is referred to as the Vector Length. The Vector Utility Software
Length is calculated by a formula that is represented below.  Search

powered by
Calculate 3D Vector Length from Coordinates

Point #1 = X0.0, Y0.0, Z0.0

Point #2 = X3.0, Y4.0, Z5.0

 
3D Length = 
SQRT ((X_P2 - X_P1) ² + (Y_P2 - Y_P1) ² + (Z_P2 - Z_P1) ²)
3D Length =  SQRT ((3) ² + (4) ² + (5) ²)
3D Length =  SQRT (9 + 16 + 25)
3D Length =  SQRT (50)
 
3D Length =  7.07106781 (Rounded to 8 places)

We now have a Tool Vector where we know the start point and end point
as well as its length. Our next issue is how do we represent this
information in a useful manner?
Since we are working in 3D space represented by the Cartesian
Coordinate System, our start and end points are represented by the
addresses X,Y and Z. Likewise, our Tool Vector can also be represented
by its component values that are relative to the linear X, Y and Z axes.
These component values typically use the addresses I, J and K. The
relationship of the vector component is defined as the directional cosine.
The directional cosines of a vector are the cosines of the angles between
the vector and the three coordinate axes.

Calculate Vector Components ( I, J, K )

 

Point #1 = X0.0, Y0.0, Z0.0

Point #2 = X3.0, Y4.0, Z5.0

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5-Axis Machining Demystified - Part One

 
X Component Distance = 3
Y Component Distance = 4
Z Component Distance = 5
 
3D Length =  7.07106781
 
Vector I = (X Component Distance)/( Vector Length)
Vector I = 3 / 7.07106781
Vector I = 0.42426406 (Rounded to 8 places)
 
Vector J = (Y Component Distance)/( Vector Length)
Vector J = 4 / 7.07106781
Vector J = 0.56568542 (Rounded to 8 places)
 
Vector K = (Z Component Distance)/( Vector Length)
Vector K = 5 / 7.07106781
Vector K = 0.70710678 (Rounded to 8 places)

For our next step, we'll want to double check our math as there is a very
important rule governing our Tool Vector components. That rule is
expressed by the equation below.

Verify Vector Components (I, J, K)

 
SQRT (I ² + J ² + K ²) = 1
SQRT ((0.42426406) ² + (0.56568542) ² + (0.70710678) ²) = 1
SQRT (0.17999999 + 0.31999999 + 0.49999999) = 1
SQRT (0.99999998) = 1 (Rounded to 7 places)

At this point you may be asking yourself why we're so concerned with the
Tool Vector components? The reason is actually very simple. These Tool
Vector components are used to calculate the Rotary Axis angles used in a
5-Axis CNC Program.
Our X,Y and Z axes are linear axes. Rotary Axis angles use the addresses
A, B and C.
The A-Axis rotates about (parallel to) the X-axis.
The B-Axis rotates about (parallel to) the Y-axis.
The C-Axis rotates about (parallel to) the Z-axis.

We are now at the point where we must consider the type of 5-Axis CNC
Machine that we will be programming.  Generally speaking, there are
three types of 5-Axis CNC machines.

The first type is one where all rotary motion is within the spindle head.
The rotary axes move to position the cutting tool at a defined vector
about the workpiece. This type of machine is often referred to as a
Head/Head or Profiling Head machine.

The second type is a machine where the workpiece is mounted to a

rotary table which is, in turn, mounted to another rotary table. This type
of machine generally has a fixed spindle that is always parallel to the Z-
Axis or perpendicular to (normal to) the XY Plane. The rotary axes move
to position the workpiece so as to align a defined tool vector to the
spindle. This type of machine is often referred to as a Table/Table
Machine or Dual-Rotary Table machine.

The third type is a machine which possesses elements of both previous

types. This type of machine is often referred to as a Head/Table Machine
. This type of configuration is typical found in Multi-Tasking Mill/Turn
CNC Machines. To keep things simple, we are going to limit ourselves to
the first two types.

Let's first deal with a Profiling Head machine and calculate the Rotary
Axis angles for a typical Aerospace Profiling CNC. For this example we'll
assume we are calculating the rotary angles for an SNK PC60-V 5-Axis
CNC.

http://www.mtbtech.net/blog/2012/11/13/5-Axis-Machining-Demystified-Part-One.aspx[3/22/2017 6:31:40 AM]

5-Axis Machining Demystified - Part One

The SNK PC60-V 5-Axis CNC has a head configuration where the A-Axis is
Primary and the B-Axis is Secondary. The SNK PC60-V has Rotary Axis
Limits of +/- 25.0° .  For the purposes of our example, we will not
concern ourselves with the physical limits of the machine. We will deal
strictly with the mathematical requirements.

The Primary Mechanical Axis of Rotation for the Profiling Head is also
Primary Mathematically. This means that the Primary Angle is calculated
first.

The Secondary Mechanical Axis of Rotation for the Profiling Head is also
Secondary Mathematically. This means that the Secondary Angle is
calculated AFTER the Primary Angle as the Secondary axis of rotation is
dependant upon where the PRIMARY axis of rotation is positioned.

Calculate Rotary Angles (A-Primary/B-Secondary) from Vector

Components

Angle A = (ATN(Vector J/Vector K)*(-1))

Angle A = (ATN(0.56568542/0.70710678)*(-1))
Angle A = (ATN(0.79999999)*(-1))
Angle A = 38.660*(-1) (Rounded to 3 places)
Angle A = -38.660

Angle B = (ATN((Vector I/Vector K)*COS(Angle A)))

Angle B = (ATN((0.42426406/0.70710678)*COS(-38.660)))
Angle B = (ATN((0.59999999)*COS(-38.660)))
Angle B = (ATN((0.59999999)*0.78086672))
Angle B = 25.104 (Rounded to 3 places)

In our next segment, we will deal with the Dual-Rotary Table

configuration.

5-Axis Machining Demystified - Part Two

3 Comments to 5-Axis Machining Demystified - Part Comments

One: RSS

H G PATIL on Sunday, February 10, 2013 11:39 AM

It is clear and easily understandable explanation
Reply to comment

arjun dhaigude on Friday, April 26, 2013 6:54 AM

tool vector is deeply explained.
Reply to comment

ahmed on Friday, January 02, 2015 11:15 PM

Dear Tim, It was very clear explanation on tool vector. Appreciate for
dissemination your vast knowledge in machining. I'd request you to write a
tutorial (similar to this) that covers how to calculate the tool vector given
tool-tip point and the value of two rotation angles for 5-axis setup of second
and third category. Thanks in advance.
Reply to comment

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http://www.mtbtech.net/blog/2012/11/13/5-Axis-Machining-Demystified-Part-One.aspx[3/22/2017 6:31:40 AM]

5-Axis Machining Demystified - Part One

http://www.mtbtech.net/blog/2012/11/13/5-Axis-Machining-Demystified-Part-One.aspx[3/22/2017 6:31:40 AM]