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Secrets of 5-Axis Machining PDF
Secrets of 5-Axis Machining PDF
I S B N 9 7 8 - 0 - 8 3 1 1 - 3 3 7 57
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Secrets
ot S-Axis
Machining
by KarloApro
IndustrialPress,Inc.
NewYork
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Libraryof CongressCataloging-in-Publication Data
Apro, Karlo.
Secretsof s-Axis lvlachining/ Karlo Apro.
p. cm.
Includesindex.
rsBN 978-0-8311-3375-7
1. l4achinetools--Numerical control.2. Machining.I. Title. IL Title:
Secretsof 5-AxisMachining.
TJ11B9.A68 20OB
671.3'5--dc22
2004027254
IndustrialPress,Inc.
989 Avenueof the Americas
New York,NY 10018
FirstPrinting,August,2008
STATEMENTOF NON-LIABILITY
No liabilityis assumedby the author or publisherwith respectto use of information
contained herein, includingfor any loss of profit or other commercial,special, or
incidental damages.While every reasonableprecaution has been taken in preparing
this book,the author and pubiisherassumeno responsibility for errorsor omissions.
Publicationof any data in this book does not constitute a recommendationor
endorsementby the authoror publisherof any patent,proprietaryright, or product,
10 9 B 7 6 s 4 3 2
Printedby ThomsonPressIndiaLimited
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Dedication
Thisbookis dedicated,
in lovingmemory/to my motherPiroska.Shetaughtme
the meaningof hardworkandperseverance. Althoughshepassedawaybeforethe
completion
of this book,her spiritcontinues
to livewith me.
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Acknowledgements
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Table of Contents
C h a p t e r 2 !K n o w Y o u r M a c h i n e . . . . . . , , , . , . . 1 3
l4ultiaxisl\4achineConfigurations .........74
T a b l e / T a b l e M u l t i a x i sf l44ai cl lhi ni nge s . . . . . . . . . . . . . . 1 8
I \ 4 a c h i nReo t a r yZ e r oP o s i t i o(nl v l R Z P ) ......21
N e s t i nPgo s i t i o n s , ............26
RotaryTableDynamicFixtureOffset . . . , , , , , , , . . . . . 27
H e a d / T a b l e M u l tl i4ai xl liisnl vg l a c h i n e s . . . . . . . . . . . . . . 3 1
H e a d / H eM
a du l t i a x i s l v l il l4l a
i ncgh i n e s . . . . . . . . . . . . . . 3 6
F i n d i ntgh e P i v o D
t istance ......37
4 - A x i ls\ 4 a c h i n e s .............3S
Genemll4aintenance
& Issuesfor 14ultiaxis
lYachines. . . 40
I\4illing
l4achinesWith Five-or l.4ore-Axes.
. . . . . . . . . . . 43
C h a p t e r 3C: u t t i n g S t r a t e g i e s . . . . . . . . . . . . . . 4 5
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Chapter4r Indexing MultiaxisToolpaths . . . , .49
i I n d e x i nl vgl e t h o d s ........,,.51
G
H o wC A D / C A |SVyI s t e m sH a n d l eI n d e x i n gW o r k . . . . . . . . 56
O*= MachineCoordinateSystems. .
Home Position . .
lulachine
ActiveCoordinateSystem . . ,
RotaryCenterPoint , .
I\4achine 60
CAD/CAMSystemOrigin . . . 60
SynchronizinglYachineand CAD/CAMcoordinateSystems .
Feedrates. .......,,72
P o sPt r o c e s s o r s . ....,........76
T o oTl i pC o n t r o l . .............90
C o l l i s iCoonn t r o l .............93
A d d i t i o nMaLl r l t i a x i s I s s u e s a n d C o n t r o l s . . . . . . . . . . . . , 9 8
D o v e tE
a fi lf e c t . ....,.......98
C u t t i nDgi r e c t i o n ..........100
I v l u l t i aRx o
i su g h i n g . ........101
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C h a p t e r TM
r achineSimulation....,..,,..,1O3
G - c o d e S i m u l a t i o n V e r s u s C A M S i m u l a t i o n . .1. 0. ,5. . . . .
C o n f i g u r i n g V i r tM
Lar ac lh i n eFso r S i m u l a t i o n . . . . , . . . . 1 0 5
VirtualMachineBuilding...,,......,...106
T h eS k e l e t o n .....106
C o m p o n e nv tss.l t 4 o d e. l.s. ...,......I07
M a c h i nSei m u l a t i Ionnt e r f a c e. s .........116
U s i nM
gachin
S ei m u l a t i .o, n. . ...,,....7I7
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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. .u.e. .s. ? 152
W h a ti s a S t a n d a rsd- A x i sl \ 4 a c h i n e ? ......153
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. ?
. ........ 154
What are the ThreeMajor Multiaxisf4achineTypes?. . . 154
What are the l'.lajorBuildingBlocksof a CNCl4achine?. 1 5 6
What are the 14ostImportantPhysicalPositionsof a
[4ultiaxis14achine? 157
What Toolsare Neededto FindMRZP?.. . 159
Description
of Indexing/Rotary
Positioning
Work. . . . . . 1 5 9
Whal i5 a PostProccessor?. 159
DefiniLion
of an Axis 160
Defininga Simultaneous
5-axisToolpath 160
Whatare the ThreeCommonSimultaneous
lYultiaxis
CAM
ToolpathConLrols. 161
14ultiaxis
MachineOffsels.. . 167
FindinglYachineRotaryZero Posilion.. . 162
Findingthe PivotDistance 164
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 .e. w
. . .. .. . 166
Pickinga CAD/CAMSystem for Multiaxis Work . . . . . . . 166
14achine
Simulation. 167
Conclusion 767
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Introduction
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History of S-Axis Machines
LongbeforeCNCcontrollersappeared,4-5-6-12-and more-axismachines,referred
to as multiaxismachines,were beingused.Ihe individualaxeswere controlled
mechanically through leversridingon cam plates.Some machineshad more than 12
cam plates,controllingnot onJytool/tableand rotary motions,but also clamprngand
unclampingof work-holdingfixtures.Thesemachineswere cumbersomeano atme
consumingto set up, but they were perfecUysuitedfor mass production.
N.ext,-the
first.rudimentaryCAD(ComputerAidedDesign)/CAM (ComputerAided
lYanLrfacturing)systemswere devejoped.At first, these softwaresoluiionswere
introducedby the same companiesthat developedthe controllers.Soonafter,
enterprisingindividLrals
wrote their own CAD/CAI4 software.Thisjump in tecnnorogy
was huge becauseit allowedengineersto draw their parts in a CADprogram,
generatea toolpathin the CAMsystemt genericlanguage,and then translateit into
multipleG-Codelanguagesquickt, usingthe appropljatepost processor.
Ivlultiaxis
machineswent througha similarprocess,but becausethev were more
complicaled,this processlook longer.First,Ihe machineswere expensiveto
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purchaseand maintain, and harder to program,Only large aerospacecompanies
had the need, the money,and the personnelto handle multiaxisapplications.Some
companieskept their own processescloselyguardedin order to gain an advantage,
Many softwarepackageswere born out of necessity- in order to solve specific
applicationchallenges.Software,in general,is alwayson the very leadingedge of
technology- pushingthe limits of softwarepossibilitiesand hardwarerestrictions.
Common Misconceptions
Most peopleassociatethe word "s-axis" with complicatedmotions such as those
for the inductionpump illustratedin Figures1-1 and 1-2, and the programming
techniquesneeded,This view is reinforcedby visits to any industrialtrade show
to see both machinebuildersand CAD/CAMvendorsshowinooff their most
complicatedcreations.
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Figure I-2 Exampleof induction pump design.
In reality,the majorityof s-axisusersdon,tevermakean impeller,or finish
portsfor a.racing-engine cyrinderhead.Mostof them machineparisusingsimpre
3-axisdrilling,contouring, and pocketmillingroutines,whileroiatingthe-part'
occasionally in a rotaryindexingmechanism, as illustratedin Figurei1-3 and 1-4.
very elaboratepartscanarsobe machinedby apprying3D surfa-cing toorpathsand
engagingthe partfrom differentanglesby indexinga rotarytable.-
Historyof s-AxisMachines
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common MisconceptionrI don't ilo enough S-axis work to warrant
a S-axis machine.
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Figure 7-8 Example of 4-axis positioning.
The abovestatementswere true in the past, but not any more. If you currenfly
own a CAD/CAMsystem, there is a good chanceyou already have s-axis
positioning capabilities.
MostcAD/cAMsystemsincludethesecaDabilities in their
basepackage.Manytimes, it is just a matter of trainingthat is neededto get up
a n d r u nni n g .
Historvof s-AxisMachines
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If you do a lot of simultaneousmultiaxiswork, the price of the CAD/CAMwill be
only a smallfactor.Moretrainingwill be needed,but you will be ableto charge
almostdoublefor your hourlymachinetime. The'hardto use'paft alwayscomes
down to training - was it easy to learn how to operateyour first CNCmachine?
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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
to build up (stacked)errors betweenmachinedsurfaceswhen they are milled
in multipleset-ups.The use of indexingrotary tables, or dedicatedmultiaxis
machines,as shownin Figures1-11 and 1-12, allowsprecisemovementof short,
rigid, high speedcutters for the best cutting engagement.More aggressivecuts can
then be taken, with higher RPMand feed rates, while the highestlevelsof accuracy
are maintained.
Historyof s-AxisMachines
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Figure 7-72 Dedicated dual-rotary machine set-up.
10 Secretsof s-AxisMachining
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Open New Possibilities
some partsare impossibreto cut on a 3-axismachine.other partswourdtake
too many set-upson a 3-axismachineto be profitable.Onceyour shopgets
comfortablewith indexingwork, you will be able to start machiningpart; suchas
thosein Figures1-15, 1-16, and 1-17, usingsimurtaneous murtiaxismotions,and
openyour buslnessto many new possibilities.
Figures 7-75, 7-76, and l-t7 More examples of parts that require simultaneous
cutting motions.
Historyof s-Axisl\ilachines 11
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Know Your Machine
CNCcontroller capabilities
The controlleris the brainof the machine.Data handling,availableon-
boardmemorysize,and dynamicrotarysynchronization controls,are
someof the thingscontrolledhere.
The lllustrations
in Figure2-1 showsomeof the varietythat existsin the machines
that make up the CNCmanufacturing industry.
13
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Figure 2-7 Typical arrangements of multiaxis CNCmachines.
TU
Figure 2-2 The spindle head and the spindle quill move along parallel axes.
14 Secretsof s-AxisMachinino
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The terms multiaxisand s-axisare often usedinterchangeably and theseterms
can be confusing.The widelyrecognized term in the industryis 5-axis,but it is
misleadingbecauseg-axisstandardpossibilities exist - withoutaddingadditional
sub-systems.In addition,a 4-axismachineis alsoconsidered to be a multiaxis
machine.Despitethe title of this book,the more accurateterm multiaxiswill often
oe useo.
KnowYourMachine 15
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Unfortunately,different machinebuildersabide by this standardin differentways.
Some buildersallow the end user to changethe machine'srotationaldirections
or behavioron the fly. Third-party rotary devices,as shown in Figure2-3 and
elsewhere,can be purchasedand mounted on a machinein a variety of ways, The
end result of this flexibilitycan causetwo machines,of the same make and model,
to have completelydifferent S-axisbehavior.
16 Secretsof s-AxisMachining
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MachineRotary Zero Position (MRZP)- On multiaxismachines, machinerotary
zeroshownin Figure2-4, is at the intersection
of the rotary/pivoting
axes.This
pointmaybe unreachable by the machine.
KnowYourMachine 17
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Whensettingup/ operating/and programmingmultiaxismachinesit is essentialto
maintainthe properrelationship
betweenthe machinezero position(MRZp) and
the programzero position(PZP).
lYultiaxis
millingmachinescan be organizedfurtherinto 3 major machinetypes:
Keepin mind that the focusof this book is milling,althoughthe line betweenthe
mill and the latheis blurringmore and more everyyear.Thereis a new breedof
multi-taskingmachinesavailablethat can do millingand turning,and thoseare
calledMill/Turnmachines.
18 Secretsof s-AxisMachining
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oneof the rotaryaxes.somewill haveunlimitedrotary motionon the otheraxis.
Someevenhavethe capabilityto spinthe work,as a lithe woutd.
Table/Table machinesare the mostcommontypesof murtiaxismachines.Most
peoplewill enterthe s-axisworldby purchasing-a
single-or dual-rotarydeviceand
boltit to their3-axismillingmachine
KnowYourMachine 19
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Figure 2-8 Third-pafty single rotary mechanism and tailstock, fastened to the
table of a standard 3-axis CNC milling machine.
After machiningone side of the work piece it is possibleto index the rotary unit
to machinethe secondside, and so on. This type of work is called indexingor
positioningwork. Some manufacturersuse specializeddual rotary mechanisms.
such as the one shown in Figure2-9, which is designedfor machininginternal
combustionenginecomponents.
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DedicatedTable/Table machinesare very capableof doingindexing/position
ing
work and are equarrycapabreof simurtaneous
work. The inherentdiflerences
betweenthe two are worth mentioning.
Evensmalldiscrepancies
will magnifyerrors.furtherawayfrom this machinerotary
zero point.
KnowYourl\.4achine 21
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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.
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2. Find the XY zero, using the dial indicator, Zero xy and A at this point, as
shown in Figure 2-13,
Figure 2-74 After rotating the A axis through 90 degrees, touch the outside
diameter of the table with the dial indicator.
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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 Secretsof s-AxisMachining
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This location is the machine's rotary zero position (MRzp), as illustrated in
Figure 2-17,
Figure 2-77 The rotary zero position of the machine, as establishedby the
outlined procedure.
Note that the intersectionof the dual rotary center lines is abovethe table in
the examplegiven.This locationwill be differentfor every machine,even from
the same manufacturer.It is imperativethat this positionbe checkedregularry,
especiallyaftera heavyworkloador a crash,Smallmisalignments can causeiarqe
errors becausethe tool positionis measuredfrom this intersectionpoint.
F o re x a m p l ec: 9 0 c 5 4 x 0 . y 0 . A 0 . c 0 .
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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.
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The advantageof using these Locar.coordinate systems is that you can easiry
followthe programon the controller,s displaysc.eenbecausethe absojute
valuesshown there will reflectthe valuesrelativeto each locally-nestedposition.
Z+1.000,for examplewill be 1.000(inch)abovethe part face.
Despitethe fact that cAM systemsa use different naming conventionsfor their
coordinatesystems/they alr handrethe rocarcoordinatesystemin a simirarway.
Some.ofthe names used by_CAD/CAMsystems include:p'art Datum, Active
Coordinate System, Local Coordinate System, System View, and Tool plane
with an Origin.
The Solution
If the operatordoesn't have accessto the cAM system/ and is unableto match
the cAl4's part positionon the machine,an option on the machinewi[ be needed
to compensate for the discrepancy
betweenthe two positions.This optionis called
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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
convenientbecausemultiple-facemachiningcan be executedby setting one point
as the referencewhen machininga complexworkpiece.
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reyE (oFFSET)
E-1grylo1selection
--+IFIXTUREOFFSETI
KnowYourlvlachine 29
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ActivatinoRTDFO:
-
00001 { P,ROGT?Ar, ZERO ) 00001 { P.eoGr?Ai,- cLoNE2 )
( D]TE A2 ]i A7 TINE 07:22 ) ( DA?a - O2-i1-07 TIME - A7:22 )
G21
c0 G17 G40 cac c90 G94 G9a G0 c17 G40 G80 G90 c94 G98
I rooL 3) D.aa. oii. - 3.1 ,,rN_ 3) Dra. ( laoL 31 Dra. a!F. 3:L LEN- 31
( G13.4 G5 Pl0O00 ) ( c43.1 G5 P1A0O0 )
T3t T3t
M6 M6
M69 M69
30 Secrets
of s-AxisMachining
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Head/Table Multiaxis Milling Machines
As their name suggests,these machineshavea rotarytableand a tilting head.
Figures 2-23, 2-24, and 2-25 Example of Head/Table multiaxis milling machines,
which have rotary tables and tilting spindle heads.
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Head/Table machinesare arguablythe most capableof the three groups
illustratedand can machinelarge,heavyparts.On some machines,the rotarvtable
can be supportedby a steady rest and it rotatesthe paft only around its own axis.
The pivotingspindleheadcarriesthe weightof the tool. It needsto be capableof
handlingthe cuttingpressuresas it is manipulating the tool.
On a Bostomaticcontroller,
for example,this resultis achievedby addingtwo lines
of code.
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these machines,it is necessaryto find the intersectionof the rotary and the
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,
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'slinearaxesalso haveto movealongthe X and Z axes in orderto
keep the tool tip stationaryin spaceas it executesthe pivoting B90 motion. CAM
systemswill makethe necessarycalculations during"post processing.,,Some
machineshavethe abilityto calculatethe necessarymotionsautomatically, based
on the offsetsshownin Figure2-31, capturedin the machinecontroller,s reqistries.
=
TANCE
PIVOT
COMPOFFSET
rbor-rr'rerrt
Fanucexamole:
G43.4, G43,5 s-AXIS ROTARYTOOL CENTERPOINT CONTROT(RTCP)
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Prog.am-Specifed
G49;
G43.4 . . . Toolcenter point function (Type 1) ON
x,l ,z, . . . (G90) The coordinatevalueof the end pointof the tool
center movement
(G91) The travel amount of the tool center
B,C . . (G90) The coordinatevalue of the rotary axes end point
(G91) The travel amount of the rotary axes
H . . . Tool length offset number
c49 . . Toolcenter point control function (Type 1) OFF
Example:
G90G00G54x0, Y0.80. C0.; . M o v e sX , t , B, C to PzP
s5000M03
G43. 4 zL . H01; . Activate RTCP. Positionsthe tool tip at Z+ 1.000
while Z axis positionis offset by offset data set for tool length
offset number 1.
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Some Head/Table machineswill use both RTCP(Rotary Tool Control Point)
and RTDFO(Rotary Tool Dynamic Fixture Offset) simultaneously.While RTCPis
offsettingthe tool positiona combineddistancefrom the head'srotary point (pivot
distance+ gage length), RPCP is compensatingfor the relativedistanceof the part
from the MRZP (Machine Rotary Zero Point) to the actual fixture position.
Head/HeadMultiaxisMilling Machines
All the rotary/pivotinomotions are executedby the spindlehead of the machine.
These machinescan be both verticaland horizontal,and they have limited
motion. Some machinescan changeheads,not just tools. Headscan be straight,
g0-degree,nutating,or continuously indexing.Someexamplesare shownin Figure
z- 5+.
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All Head/Head machineshavedifferentbehavior;basedon indlvidualinstallation
settings.Rotarydirections,limits,retractions,rotarywind-up,and handling
singularitiescan all be alteredfrom factory settings.The most impoftant basic
dimensionneededis the rotary/pivot center pointr which is measuredfrom the
spindlefaceto the head'srotaryposition.Machinemanufacturers sometimes
providea nominalvalue,but it is essentialthat the manufacturer's value be
double-checked/ especiallyif it is a nice roundnumber,for instance,10 inches.The
roundnessis a good lndicationthat the numberis not accurate.
KnowYourl\,4achine 37
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Figure 2-36 Touching the dial indicator plunger is eased by having a wide, flat
top on the plunger.
Do not move the machineon the X axis. Moveonly on the Y and Z axes. Move
to a safe point on the Z axis, and rotate the A axis through 90 degreesinto a
horizontalorientation.Next, move on the Y axis in the plus and on the Z axis
in the minusdirectionsuntil you get to the positionshownin Figure2-37.
38 Secretsof s-AxisMachining
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Youshouldhavethe followingvalueshandy:
Z maximum
Z minimum
GL - Gage Length
R - Dowel pin radius = .5OOO
Formula to calculate Pivot Distance:
PD=Zmax-Zmin-GL+R
4-Axis Machines
If a third-pafty,singlerotary mechanismis placedon a 3-axismillingmachine,it
becomesa 4-axismachine.The most oopulardedicated4-axismachinesare the
horizontaltypesshownin Figure2-38.
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Thesemachinesare mostlyusedfor tombstonework, wherepartsare clamped
to all sidesof the tombstonefixture and machinedby rotating them into different
positions, The chipsdon't collecton the work-piecebecausethey fall away by
gravity and are cleanedoff by strategically-placedcoolantnozzles.
Somecommonoroblemsinclude:
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Figure 2-4O These rotary mechanisms appear to be intersecting.
KnowYourMachine 41
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Figure 2-47 Indicating run-out.
The machinetypes describedin this chapter are built by many different machine
buildersin a variety of sizes,shapes,qualities,and prices.The quality of a machine
will be best highlightedwhen fast. simultaneous, multiaxismotionis beingused.
A good-qualitymachinewill executethese motions quickly and repeatedly,in a
smooth synchronizedway, without one rotary axis waiting for anothel and without
backlashor vibration.The rotarymechanisms will haveminimalrun-out,and the
rotary centerlineswill align precisely.Cheapermachinesmay execute positioning
movementswell, but will executesimultaneous motionspoorly.
42 Secretsof s-AxisMachining
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Milling Machineswith Five or More Axes
lVostmachineswith more than five axes are built for specificmanufacturing
applications,Some examplesincludethose shown in Fioure2-42:
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E A simpleexampleof sucha subroutineis an M06,whichcausesa tool change.
Observecloselywhat happenson any machinewith an automatictool-changer:
the machineslidestravel to pre-determinedlocations;the tool-changecarousel
advancesthe chosentool; a little trap door may open, dependingon the
machine;then a swing-armwill exchangethe tool betweenthe spindleand the
carousel. This whole choreographyis just one of many internal macros,ready
to be activatedby a simple code like M06. On multiaxis machines,many more of
these internal macrosare available.Most of the time, the macrosneed to work in
svnchronization,
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Cutting Strategies
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The singlemost importantpart of mu tiaxis programmingis the initialtime that
is spenton decidinghow to tacklethe job. I\4achining
sequencesshouldbe kept
simple,not made complicated just becausethe shop has the latestequipment,the
most powerfu CAD/CA[4 system,or an unlimitedbudget.Hereare some questions
that needto be considered:
Do you have to use existing fixtures or can you make your own?
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Determine Fixturing
Checkon availablefixtures,vises,and clamps.Useexistingvisesand fixtures
wheneverpossible,to keepthe costsdown. The equipmentshouldbe modeledin
the CAD/CAMsystemand organizedinto librariesthat can be readilyaccessedand
loadedfor virtual simulationwhen checksare madefor possiblecollisions.
CompareMachines
If more than one machineis availablefor the job, some comparisonsshouldbe
made.Amongessentialchecksare: work envelopelimitations,maximum RPIY,
feed-rates,and controllercapabilities.
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Indexing Multiaxis Toolpaths
Figure 4-7 Images showing how one part can be cut from many different angles,
without being removed from the fixture.
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Figure 4-7a Images showing how one part can be cut from many different angles,
without being removed from the fixture.
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The conceptmay be simple, but it allows for the manufactureof very complex
parts with precision,like the samplesshown in Figures4-2 and 4-3.
Indexing Methods
There are many different indexingmethods,and they can pedormed with
equipmentas simple as a manually-operated,custom indexingfixture. Third-party
autonomousrotary devicesalso are available,which will executepre-programmed
indexingsequencesat every cycle.The cyclescan be activatedmanuallyor through
a dedicatedM-Code.If one of these methods is used, great care must be taken to
synchronizethe manual operationswith the Nc-code,Ample opportunitiesexist to
make a mistakewith these methods.
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The best method is to use fully-integrated. third-party, rotary devices,which will
executerotary commandsdirectly from the Nc-code.For these methods,the rotary
pivot center must be preciselylocated(as describedin Chapter2).
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Figures4-8 and 4-9 show some examplesof dedicatedmultiaxismachine,rotary
mechanisms.
Figures 4-8 and 4-9 Some examples of dedicated rotary machine components.
Figure 4-7O Spindle heads on some machines are designed to be straight, set at a
specific angle, or even adjusted steplessly to various angles.
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Othermachines,usedmainlyin the medicaland aerospaceindustries,are designed
to indexand hold the part with grippingaxeswhile machining.Examplesof these
types of machinesare shown in Figures4-LL and 4-I2.
Figures 4-77 and 4-12 Some machines are designed to index and hold the part
during machining.
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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.
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How CAD/CAMSystems Handle Indexing Work
BeforediscussingCAD/CAMsystem applications,it is importantto establishsome
of how CNCmachineswork.
core understanding
tz
Figure 4-75 Positioning two fixtures with parts on a machine and assigning
individual local coordinate systems.
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Machine Coordinate Systems
Machine Home Position
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Figure 4-76 Multiplenestingpositionson a tombstonefixture.
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t/
t
\
Figure 4-78 Central coordinate system on a single part.
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Usinga singleActive Coordinate System requiresthat only one positionbe
indicatedon the machine.This approachsimplifiesthe processand lessensthe
possibilityof error.
So far it has been establishedthat every machinehas its own Home Position,
which is its center of the universe.Every localcoordinatesystem is a relative
locationin that universe.Also, the intersectionof the rotary axis, commonly known
as the Machine Rotary Center Point, is a relativelocationin that same universe.
and its positionis stored in the registry.
CAD/CAMSystem Origin
EveryCAD/CAMsystem also has its own universe.They all have a world zero,
Master Coordinate System, System Origin, and so on. Just like machinetools,
all these locationsare called by different names.One thing you can be sure of -
noneof them will havethe same Home Position as any other machine.The job of
a CAD/CAMuserand CNCmachineprogrammeris to alignthe worldsof both the
machinesand the CAD/CAMsystems.
If the One Zero method - where the local coordinatesystem on the machine,
which is the Machine Rotary Zero Point - is in use, it is possibleto simply
match the CAD/CAMSystem'sWorld Zero with that location.The part must then
sit in the same relative locationand orientationfrom the Machine Rotary Zero
Point of the systemand the machine,as seenin Figure4-19.
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It on the otherhand,the multiplenestingpositionmethodis preferred,new
Active CoordinateSystems must be createdin the CAD/CAM systemas shownin
Figure4-20.
Figure 4-2O The relationship of the part zero to the Machine Rotary Zero point.
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,
"p{
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Figure 4-22 Complete Machine Simulation.
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Figure 4-23 Virtual -axis horizontal machine for simulation purposes.
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SimultaneousMultiaxisToolpaths
The illustration
in Figure5-1 showsa 2-axismachinecuttinga patternonto a
bowlingball.This machineonly has a tilting B and a rotatingC-axis.Thereis no
Z axis. Instead,that motion is controlledby a softwareM code, which has an ON
and OFFstate - either loweringthe tool onto the part, or lifting it to its reference
Dosition.
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c01 22.0000 F90.
x - 5 . 5 A 2 8 8 0 . 0 0 0 F 5 0.
GOO25.
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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.
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An exampleis the spiralbevelgear shownin Figure5-6, whichwould normallybe
producedon a specialgear-cuttingmachinein an automobileplant.
02000
G91G1Z-.1E50.
x2.22-.1C60.85. (4-axis simultaneous motion)
x - 2 . 2 2 . 1 C - 6 0. B - 5 .
M99
03000
M98 P2000 i,3
G91G002.3
zr.
c72.
lt-L.
M99
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This last exampleis very simplistic,but with somecreativeuse of branching/looping
logic.Someshopshave usedthis techniqueto producevery complexparts.
CADsystemshaveevolveddrastically
and, as a result,it is possibleto designand
manufacture
ever-morecomplexparts like the examplesshownin Figure5-7.
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MultiaxisToolpaths 69
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Figure 5-7 Examples of parts produced on multiaxis milling machines, including
turbine blades and rotors, impellers, pump components, brackets, and manifold
covers.
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Figure 5-8 A vertical milling machine with a trunnion-type duat rotary tabte, set
up to machine a model of a human head.
Figure 5-9 Example of part being placed far away from MRZP.
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In Figure5-9 it should be noted that the B-axis move is much longerthan the
C-axismove, even though the angularvaluesare the same. The reason,of course,
is that the circumferencesare widely differentfor the B and C motions. High-
quality machineshandlethese kinds of unevenrotary motions better than lower-
quality machinesbecausethey synchronizethe two rotariesto arrive at the same
point, while maintaininga constantfeedrate.CAD/CAMsystemscan also control
feedratesby using Inverse Time Feedrate output. A more detailedoverviewof
these controlsis includedin the Feedratessectionof this chapter.At this point, it
is sufficientto know that it will be much better to placethe workpiececloserto the
same rotarydiametersof the specificmachine.as shownin Figure5-10, especially
if a third-partydual-rotarytable,or a lesserqualitymultiaxismachineare in use.
Figure 5-7O The part is placed close to the Rotary Zero Point of the machine.
Feedrates
On a 3-axis (non-rotary) machine,there is no need to specifya feedratemode
becausethese machinesall operatein the units/time mode.
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Figure 5-77 A diagonal groove is machined by moving both tabte stides
simultaneously using linear interpolation,
Figure 5-72 Circular interpolation is used to move the workpiece in a circutar path.
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A planarcirclecut usinga c3 r-5. F10. commandis illustratedin Figure5-12.
The resultingmotionappearsto be a true circle,but it is not. Any machinethat has
the standardthree XYZlinearaxescannotcut a true circle;only an approximate
one.The slideson these machinescan move only in straightlines.Therefore,in
orderto generatea circularpath,the controllerwill haveto interpolatea circular
move by breakingthe programmedcircleinto a numberof straight-line segments.
On most machines,the circulartolerancecan be set from insidethe control
parametersettings.The largerthe sizeof straight-line segments,the lessaccurate
the circleswill be. A smaliernumberwill resultin more accuratecircularcuts.
The exampleshownin Figures5-13 and 5-14 has only one rotary motioncombined
with X and Z linearmoves.
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Figure 5-73 The start position for machining a complex parc.
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Multiaxis
Toolpaths
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Lookingat the two illustrations in Figures5-13 and 5-14, it is possibleto observe
and imaginethe differencein travel distancesbetweenthe tool tip and the rotary
centerpoint of the head.To maintainthe programmedfeed/minuteon the tool tip,
the center of the rotary spindlehead needsto move very quickly.This scenario
can be comparedto runnerson a track. Runningin the insidelaneof the track
coverslessdistancethan runningon the outsidelaneof the track.The tool tip is
the runneron the insidelane,and the centerofthe rotaryis runningon the outside
t an e .
In short, the machineshould not be instructedto move from the current positionto
the destinationat X units per minute.Instead,it shouldbe told to movefrom start
to destination,in X amountof time, in a smoothinterpolated motion,on all the
axes involved.On Fanuctype controls,G93 signifiesthe staft of the inversetime
mode.Theremust be an F commandat the end of every line containinga G1, G2
and G3 code.The Inverse Time mode will not affect rapid G0 moves,
Inverse Time Feedrates were widely used in the early days of NC, but today
many modern CNCcontrollersare capableof parsingstandardfeedratesinto
inversetime and vice-versa.(A parseris a compileror interpreter).Usually,an
inversetime smoothingalgorithmis incorporated into this featureand it can be
parametersetting.
enabled,or disabled,in the controller's
Post Processors
CAD/CAMsystemsgenerates-axis vector lines along 3D paths.The 3D paths
representthe tool motion as it followsthe pattern being cut. The vectors represent
the individualtool axis directions(IlK vectors)as the tool followsthe 3D (XYZ)
pattern. Everyvector is representedby a line of code, and during toolpath creation,
a resolutionof these vectors can be specified,either by definingthe minimum
angulardifferences,or the linear distancesbetweenvectors,This informationis
writtenin a genericlanguage.Depending on the CAD/CAMsystem,the language
may be calledAPT,CLS,NCI,and others.Machinetool controllersdo not speakor
understandthesegenericlanguages, howeverthey do understandmany different
languages and dialects.
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to machinethe part. A different post processorwill be neededfor every type of
multiaxismachinein the shoD.
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lYanyCAMsystems handle safe motions betweentwo subsequent.toolpath
operationswith post processors.Thesecontrols retract the tool into a safe
area, and a s-axis machinerepositionsfrom one operationto the next.
Instead of simply retractingto the MachineHome Position,safety volumes
(box, hemisphere,cylinder)can be used for efficienttool retraction.Keepin
mind that an efficienttoolpath doesn't make erratic and unnecessarymotions
- it retractsthe workpieceonly to a minimum safe distance,and keepsthe
cutterengaged,while maintainingall machineaxesin optimumpositions..
lot of effort,
Developinga post processorfor multiaxismachinestakes a "hackers"
talent, professionalism,and perseverance.There are many who are
managingto "make it work,"but a high-qualitypost processoris suppliedwith
detaileddocumentationand user-definedswitches.
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Common SimultaneousMultiaxis
Toolpath Controls
A good CAD/CAMsystem is one of the most importanttools in a modern machine
shop,and will provideenoughcontrolto confidentlydrive any multiaxisCNC
equipment.The three major thingsthat needto be controlledare:
In additionto those three major controls,which are definedin more detail in this
chapter,good-quality CAD/CAN4 systemsalso provideadditionalcollision-avoida nce.
This insurance will recognizethe tool'scutteLshank,and holder.Differentavoidance
behaviorscan be invokedwhen any of thesecomponentscomesinto proximitywith
the work-pieceor a fixture. Differentnear-misstolerancescan be assignedto each of
these tool comDonents.
Cut Patterns
Cut Patterns guide the tool along specifiedpaths.These patternscan be simple 2D
or 3D wireframe,or solidprimitives(for example,box, cylinder,and sphere.)Cut
Patterns can also be complexmulti-surface grids.
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Figure 6-7 Tool motion following a 3D curve projected on to the face of a workpiece.
Figure 6-3 A Cut Pattern is selected to slice the part in any given plane, for
example, patterns 3 or 4.
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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.
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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,
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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.
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Figure 5-72 Path following a spherical Cut Pattern.
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Figure 6-74 Axial Cut Pattern on a Figure 6-75 Radial Cut Pattern
turbine blade. on a turbine blade.
Figurc 6-76 Turbine blade's foot sufface cut by morphing the Cut Pattern
between the outer edge of the foot sufface and the blade surface.
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Figure 6-77 Cut Pattern following the natural flow of the surface - the grid lines.
Figure 6-78 The Tool Axis can be locked Figure 6-79 The Tool Axiscan be
normal to a plane. In this example, the lockedso that it always intersectsany
Tool Axis will be maintained normal to definedDointon the holderside.
the bottom floor surface of each
individual inseft Docket,
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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 6-22 The Tool Axis can be forced to fo ow a chain, while spiraling
down an intake or exhaust channel.
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6-23 The Tool Axis is controlled by the curves of the top
and bottom surface edqes.
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In additionto the previouslydescribedTool Axis Control Methods, more controls
are availablethat allow the tool to be rotated around its tip by specifyinglead, lag,
and sidetilt angles,as shownin Figures6-26 through6-30.
Figure 6-26 Tool axis normal Figure 5-27 Tool axis at a lead angle.
to a surface.
Figure 6-28 Tool axis at a lag angle. Figure 6-29 Tool with side-tilt angle.
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Newersystemseven allowdynamicchangesto be madeto the side tilt, or the
lead/lagangles,whilecutting.The examplein Figure6-30 showsturbineblade
machiningin whichthe Tool Axis is dynamically controlled.With this control,the
tool can be providedwith optimum accessto all the featureson the blade in all
staoesof the cut.
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Figure 6-37 Generating tool positions on the cut pattern.
Next, they will move the tool to a desireddepth along the ToolAxis, basedon
the Tip Compensation method.
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Forexample,surfacesgeneratedto controla toolpathfor the humanheadshownin
Figure 6-33.
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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
or gougesare alwaysto be avoided,so why is collision
control needed?Why aren't all CAD/CAN4 Systemsdesignedto avoid them
automaticallv?
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The CNCprocessis very good at reproducingshapesand comes in handy for this
application.The challengeis getting these hand-carvedshapesinto the CAD/
CAMsystem. Probingis a common method usedto reproduceports, A probe is a
sphericalinstrumentthat is used to touch the part and record a point in space,
Touchingmany pointswill recordwhat is knownas a pointcloudwhichis a group
of pointsthat roughly representsthe part's shape.If a probe of the same diameter
as the tool to be used is employed,the tool can be guided along the points in this
point cloud to cut the part. An exampleof a shapeto be reproducedis shown in
Figure.5-36, and a close-upof the probe in contactwith the surfacesin Figure
6-37.
Figure 6-36 Probe being used to generate points over the part's surfaces.
Figure 6-37 Close-upshowing contact of the probe with the partb surface.
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In some instances,it may be advisableto use a tighter cutting grid to obtain
a better finish, or to use a different size of tool. In these conditions,it may be
necessaryto transform the point clouds into workablesurfaces.Thesesurfaces
would exist relativeto the center of the probe and, in this situation,it would be
necessaryto lead the tool center on the surface,(the same place where the probe
center was) thus gougingthe surface.
Figure 6-38 Theseport surfaces were generated on the probe's centerline. The
tool center is led on to the surfaces,
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Figure 6-39 This probe sutface was generated with a laser scanner that can
represent the true shape of the port,
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Figure 6-40 A warped impeller.
. Specifythat cuts should start from the top and work down toward the bottom
of eachblade.
. Specifyuse of a tapered-shankball-nosecutter.
. If the cutter's shank comes within a certain distancefrom the blade,the tool is
instructedto tilt away, either in the lead/lag,or the side tilt directions.
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Figure 6-47 A Clean Cut Pattern with dynamic tool axis control.
Not all CAD/CAMsystems providethis amount of control. Some will only allow the
definitionof check surfacesto be avoided,but will not orovidethe meansto avoid
them. Keepin mind that thesecontrolsfocuson collisionsbetweentools.holders,
fixturing,and work-pieces.They will not avoidpotentialcollisionson the machine.
To avoid collisionsbetweenmachinecomponents,like rotary headsor tables.
machinesimulationis needed.That subiectwill be coveredin the next chaoter.
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EOVETAIL
Figure 6-43 For cutting a spiral sptine, the tool must be moved off center.
The offset amount must changefor each side of the spline,and the offset amount
will dependon the pitch of the spline. Note also that the bottom center of the tool
face cannot be in contact with the minor diameter.
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Cutting Direction
lYostcutters are very sensitiveto the cutting direction.In the 3-axis world, it is
easy to see and define cuts that are conventionalor climbing,but this is not true
when cuttinga multiaxispart.
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Figure 6-45 Lead cut engagement in
milling.
Multiaxis Roughing
There are many instanceswhere it is necessaryto use long tools for roughing,as
seen in Figure6-47. This is usuallydictated by the part features.Impellersare
a good exampleof this problem.Tall bladeswith small gaps betweenthem force
the use of a long cutter, and these cutters don't perform well with side-cutting
pressures,As the side-loadincreases,these tools will deflect,causingvibration,
chatter,poor surfacefinish, and drasticallyshorter tool life. Multiaxisplunge
roughingis a good way to remove material in these circumsrances.
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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 manageabledepth, plungeout one layer,then pick away on
the next one. The cutting pressurewill be along the tool axis. This procedurewill
eliminatetool deflectionand all its negativeside effects.A typicaljob produced
with this procedureis shown in Figure6-48.
Some CAD/CAMsystems also have the ability to look at the shapeof the stock
model and eliminateall air-cutsfrom the toolpath.This ability,combinedwith
plungeroughing,can shaveoff hoursfrom high-volumeroughingoperations.
Plungeroughing is not a simultaneousmultiaxiscut and therefore is a more rigid
cut.
Figure 6-48 This part was cut out of "green ceramic" which gets fired after
milling. The finished component is resistant to abrasive chemicals in high-
temDerature environments.
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MachineSimulation
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a newrunproven/5-axisprogramblindlyon a machine,is Iike playingRussian
roulettewith the gun chambersfully loaded.UsingmultiaxisCNCequipmentas a
verificationsystemdoesn'tmake sense,and is much more expensivethan using
simulation.But with that said,nothingcan substitutefor the real thing, Evenafter
simulationtests,the first run will alwaysbe exciting.The sights,the sounds,the
feel of the cuts are irreplaceable.Machinesimulationis not a magicbullet,but used
properly,it is an extremely helpfultool.
Realities
Evenwith today'sadvancesin CAD/CAMcapability, many peoplestill manuallyedit
the code created by their CAMsystem.There are various reasonsfor this and some
of those reasonsincludethe followinq:
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systemsfirst generategenericintermediatecode (APl NCI, CLS)and then post
processthat code into the machines'specific
G-codelanguage.All NC machines
understandG-code,and when they readthat code,they translateit into machine
motions.Everyword in that code, regardlessof where it comesfrom - the CAM
systemor manualediting- will be recognized withoutdiscrimination.
The most
commonquestionis whetherto simulatethe intermediatecodeor the G-code.
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If true G-codemachinesimulationis the goal,Vericutby CGTech, is the best
solutionbecausetheir apDlicationsteam has hundreds of years of combinedhands-
on G-codeexperience and is capableof configuringany type of CNC machine,
even entiremachiningcells. The company specializes in reverse-post processing,
meaningthat they start with G-codeand convertit to machine movements, just
like a machine'sCNCcontrollerwould.
SomeCAMsoftwarepackagesoffer multiplemachinesimulationinterfaces.
A few havedirectinterfaceswith Vericut.Anotherpopularchoiceis Machsim
by Moduleworks.The equally-capable Moduleworks in post
team specializes
processorsconfiguredto produce both the simulationand the G-codeoutput.
Virtual MachineBuilding
It is not necessaryto virtuallybuildan entiremachineincludingthe chip conveyor,
NC controller,coolanttank, and so on. Sucha processmakesfor slicksimulation,
but the only crucialpart that needsto exactlyresemblethe real machineis the
area nearthe workingenvelope.Thesemotionsmust exactlyreplicatethe real
machine.The remainderof this chapterwill coverthe processinvolvedto virtually
buildall the major machinesthat were coveredin Chapter2. The stepsare very
similar,regardlessof the simulationsoftwarebeingused.
The Skeleton
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C "€,tor,,-.
a z _E MoDELS
B-
EBrrrooels
TOOL
eY_^
{JMODELS
a x__ I+IMODELS
€tA--
LTJMODELS
sTocK_
€BMoDELS
The secondbranchis also attachedto the BASE' starting with the y-linear axis
component.Observethat Y is at the same indentationas Z. The y-axis is carrying
the x-linear axis component.X is carryingthe A-rotary axis component,which
in turn is carryingthe STOCK,or workpiece.This kinematiccomponenttree is
the most basicdescriptionof a machine,and is a stripped-downskeletonof the
machine.There are no modelsattachedto this skeleton,but you can tell by a
glancewhich bonesare connectedtogether.
Components vs Models
MachineSimulation 107
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different propertiesto be assignedto each of the models.Uniquetolerancevalues,
colors,translucency,visibility,and reflectivitycan be assignedto each model,
and individualmodelscan also be includedor excludedon the collision-detection
settings.
.' BASE
>B
a srocK
3x
$ rool
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ar BASE
3Y
3x
>B
)a
rtsrocK
3z
$rooL
Figure 7-3 Vertical 3-axis machine, converted to s-axis with a third-party dual
rotary device.
MachineSimulation 109
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ar BASE
3V
>A
>c
ItsrocK
€x
az
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Figure 7-4 Verticat s-axis machine with a dual, rotary, nutating table'
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.' BASE
ex
az
$rool
€Y
?a
>c
rtsrocK
Figure 7-S Vertical s-axis machine with a trunnion-type dual rotary table.
MachineSimulation'l'l'l
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.' BASE
*Y
3x
az
$rool
>B
>c
a srocK
Figure 7-6 Vertical s-axis machine with a dedicateddual rotary table.
'l'12
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.' BASE
OX
az
>A
$rrool
€Y
>c
asrocK
lvlachineSimulation113
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.' BASE
€x
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ez
>B
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Da
o srocK
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.' BASE
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Simulation 115
Machine
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'BASE
3x
az
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3Y
a sroc
Figure 7-7O Vertical s-axis laser machine, with a dual rotary head.
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Using MachineSimulation
Thesedays, very few peopleprogram exclusivelyby hand. Most peopleuse a CAD/
CAlvlsystem to generatecode.The palt is typicallyeither designedor imported,
and then toolpathsare generatedusingtoolsfrom an internalor an external
library.Machinesimulationcan be run at any time duringor at the end of this
process,providedthe groundworkhas beenlaid down and the machineshavebeen
b uilt.
't17
l\ilachine
Simulation
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SelectingThe Right Machine
For Your Application
Makinga multiaxisequipmentchoicedecisionis similarto choosinga car make
and model.The decisionneedsto be basedon the intendeduse, budget,and
personality,
alongwith many other considerations. The multiaxis\\garage"includes
the equivalentsof racecars,all-terrainvehicles,buses,and luxuryvehicles.There
are general-purpose machinesand there are machinesmadefor specificapplications.
This chapter may help narrow the searchbasedon the specificparts being
manufactured.
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tr Selecta machinemanufacturerthat suitsthe applications criteria,and then take a
good look at the variety of pafts currently being manufacturedin your plant. Also
considerthe partsyou intendto manufacturein the future.Considerthe following
scenarios.
Are your existing CNC machines waiting for programs, or are your CNC
programmers waiting for a free machine?
If existingequipmentsits idle waiting for programs,then the workflow,CAD/
CAMsystem capability,and programmers'andoperators'proficienciesneed to be
scrutinized.If programmersare waitingfor free machines,it is againa good idea
to checkthe CAD/CAMsystem'scapability.Couldthe cutting strategy be improved?
Are the right tools beingused?Imaginerunningold style high-speedsteeltools on
a modernCNCmachinecapableof 40,000 RPMand 1500 IPM - the limitationsof
cheaptoolingcouldhold backa very capableand very expensivemachine.In the
same way, if your CAD/CAMsystem is obsolete,you won't be able to use your CNC
equipmentto its full potential.
Are you happy with the performance of your CAD/CAM system, and are you
using it to its full potential?
Makesure that your CNCprogrammers are up-to-datewith their trainingon your
CAD/CAMsystem to ensure it is being used to its full potential.It is much cheaper
and easierto get organized,trained, becomeefficient,and promote teamwork, than
it is to buy a brandnew machineand put it into production.
120 Secrets
of s-AxisMachining
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New Possibilities
After determiningthat your shop is runningfull out and needsadditional
equipment,it is time to considernew possibilities. The first obvious
consideration is the physicalsizeof the machine,and that is dictatedsimply
by the sizeof the partsthat will be machinedand the sizeof your shopfloor.
The next consideration is the materialthat will be used,whichwiil determine
the rigidityneeded.The qualityrequirements of the machinewill be affected
by the expectedtolerancesyou want to hold, and budgetaryrestraintsmust
also be kept in mind. Asidefrom theseproperties,keepin mind that some
multiaxisequipment is better suited for certain types of work than others,
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An airplanewing stringeris a goodexampleof a part that is long,but very slim.
Partslike this are typically machinedfrom specialextrusions,which can be over
40 feet long.Typically, parts likethesewere madeon machinessimilarto the ones
shownin Figures8-2 and 8-3, usingmultipleset-upsand elaboratefixturing.
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Figure 8-4 Dedicated extrusion milling machine.
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These Dartswould be best manufacturedon the Head/Table machine
configurationshown in Figure8-6.
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Figure 8-7 Head/Table engine head-port milling.
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The machinepicturedin Figure8-7 is designedto rotate the head around its center
of mass without generating unwantedcenfrifugalforces' The machinein Figure8-8
"nock-and-Roll" dual-rotarydevice.It is designedespecially
nas sometningcitted a
for machining-portson engine heads.The entire fixture holdingthe part is rocked
una |.ori"athioughout thelutting processto presentthe work to the cutter.These
fixtures need to be carefullybalancedto ensuresmooth motion'
Head/Table Machines
Head/Table configurations suchas thoseshownin Figures8-9, 8-10' and 8-11' are
urnon6tn" most virsatile choicesfor a variety of other multiaxisapplications.This
""rr"t]f ii'l"ri"es from the fact that the steady rest can easily be removedand the
spa."canbeusedformountingadditiona|fiXtures.CustomizedfiXturescana|sobe
built to suit specialjobs.
Figure 8-77 Machining an auger feed spira! for an injection molding machine'
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Figure 8-72 Machining a rotary windmill unit.
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Rotary Table- Tilting Head Combinations
Theexampleshownin Figure8-14 blursthe linesomewhatbetweenthe vertical
and horizontaldefinitions.
Figure 8-74 This Head/Table machine is available in both vertical and horizontal
configurations,
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Secretsof s-AxisMachining
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Figures 8-75 and 8-76 Head/Table aerospacetand Head/Table automotive
applications.
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All rotary-table,tilting-headmachinestend to rotate the workpiecesaround their
centersof mass while maintainingthe capabilityto reachall their featuresby tilting
the head.Thesemachinesare built in many sizesand are widelyusedin many
different industries,from manufacturingsmall medicalparts (Figure8-19) where
precisionand speedare the main requirements.to manufacturinglarge earth-
movingequipmentparts (Figure8-20), whererigidityand horsepower are the
focus.
Figures 8-79 and 8-2O Typical medical part, and heavy equipment component
manufacturing.
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Figure 8-27 Typical plastics-mold cavity.
Figure 8-22 Multiaxis machining allows for the use of shorter, tapered cutters,
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Table/Table Machines
Figures8-23 and 8-24 show the most commonconfigurationsof Table/Table
machines,The partsto be machinedare clampedto a dual-rotarytable and
are rotated around the tool, Inertia is a consideration.The dual-rotarytable is
either mounted on the machinetable or is a dedicateddual-rotarycomponentof
the machine.These machinesare not suited for manufacturinglong parts' The
work envelopeis fairly limited, especiallywhen some tool changerlimitationsare
considered,Despitethe limitations,this configurationis very popular.
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Table-mountedunits are not completelyrigid, but dedicateddual rotariescan be
both agile and rigid. They are equally well suited for 3+2 indexingwork, and for
simultaneousmultiaxiswork. Some applicationsare 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.
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Gantry Type Head/Head Machines
cantry type Head/Head machines,as shown in Figure8-29, arc used for large
parts, mostly in the aerospace,oil, and wood industries,This configurationpermits
long lineartravels.Some machinesare designedto allowchangesof heads
in additionto tools. Rigidityand precisionmay not be the strong suit of these
machines,but long reach capabilityis.
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Figure 8-3O A s-axis laser cuttinq machine.
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Figures 8-32 and 8-33 A 6-axisindustrialrobot, and a 7-axisindustrialrobot.
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Choosinga CAD/CAMSystem For
Your Application
Choosingthe appropriateCAD/CAMsystem is as important, if not more important,
than choosingthe most suitablemultiaxismachine.Thereare many specialized
machinesthat are dedicatedto specifictypes of work, howeverone CAD/CAMsystem
will driveall the CNCequipmentin the shoD.
It is importantto make sure that the selectedsystem can handlenot only all the
differenttypes of work the shop does now, but will also be capableof taking on
futurechallenges.
Systemswith heavy CAD emphasishave their roots in CAD and are better at solid
modelingso that they can handle large assemblieswith ease.Thesesystems have
associativitybetweenall the componentsso that when a changeis made to one
feature on one part in an assembly,it will propagatethroughoutthe entire assembly.
Thesesystemsare very good at managingCAD data, but their CAMcapabilitymay
have been added later and it often does not have the same deDth.
't37
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automatedcuttingstrategies. A toolpathis soongenerated,posted,and ready-
to-go.The trade-offfor this speedand easeis realizedwhen engineeringchanges
are necessary,Those changesneed to be made on a separateCAD system and
imported back into the CAMsoftware.Also, these specializedCAIYsystemswill
not suppoftany other kind of CNCmachines(lathe,EDM,plasma,waterjet,etc,)
and many won't even supportsimplecontour,drill, or pocketroutines.Thistype
of specialpurposeCAMsoftwareonly makessensefor shopsthat are machining
largemold cavitiesday in and day out. It may be necessaryto purchasea separate
programmingseat of CAD,and maybeeven anotherseat of generalpurposeCAl4.
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CAD/CAM Toolbox
Buyinga CAD/CAN4 system is like buying a fully stockedtoolbox, but care must
be takento ensurethat it containsthe right toolsfor the job. All tradesmenhave
their own ideaof the perfectset of tools.A perfectset of sharp,high-qualitychisels
wouldbe uselessto an electrician. At the sametime, it would be cumbersometo
usea SwissArmy knifeas a screwdriverall day long.
Very few CAD/CAMsystems can do everythingwell. They all have their strengths
and weaknesses. On the other hand,very few companiesneedall the power
affordedto them by a modern CAD/CAMsoftwaresystem.The trick is findinq the
right balance.
Multiaxis CAD/CAMConsiderations
Multiaxismanufacturingrequiressoftwarethat is very strong in CAlv.CAD
capabllityis needed,but mostlyto import CADfilesfrom all the major CAD
systems,in all the popularCADdata formats.On top of that requirement,
additionalCADcapabilityis neededto createsuppoftinggeometryfor tool axis
control,fixturedesign,or virtualmachinebuilding.
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Multiaxis CAM
The categoryof 3+2 indexingwork requiresthe ability to quicklyand easilychange
the work planes,which are alwaysperpendicularto the spindle/toolaxis. The
creationand manipulationof these work planes,also known as Active Coordinate
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.
consider mold and die work as an example.This work is one of the most
demandingand accuratefields in manufacturing.Moldscannot be mass-produced
but are made one or two at a time, and they have predictablefeatures,either a
core, or a cavity,or a little of both. A good 3-axis roughingstrategy will always
work well here. Some CAMsystemscan quickly and automaticallyanalyzethe
featuresand then automaticallygeneratea toolpath to machinethem' In this
shotgun approach,a wide field of targets can be coveredwith one shot.
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Tool Axis Control
Toolaxis control providesthe ability to set and manipulatethe center axis
alignmentof the tool duringthe cuttingprocess,as illustratedin Figure9-2.
Thesecontrolscan be dynamic or static, but it is essentialthat they work in a
predictable,stable way.
Figure 9-3 Tool tip compensated to follow the outer surfaces of the work.
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Collision Avoidance Measures
Care must be taken to avoid potentialcollisionsbetweenmoving components/
and betweenmoving and stationarymachinepads when multiaxistoolpaths
are being generated,As illustratedin Figure9-4, this particularcontrol focuses
on meansto avoid collisions,particularlybetweenthe cutter,arbor, holder,and
the workDiecefixture assembly.
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Machine Simulation
Machinesimulationeliminatesthe guessworkand the needto prove-outnew
machiningprocesseson real machines,Usinga real machineto prove-outa
toolpath wastesvaluableproductiontime and risks potentialcollisions.User-
friendly 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
CAD/CAM software. Without post processing,parts can be cut only in the
virtual world and not on real machines.The role of anv CAMsoftwareis to
generatecode that will drive the movementsof the axes on a CNCmachineso
that a part can be machined,The native CAMlanguagemust be translatedto
matchwith eachmachinet specificlanguage.Customized multiaxispostsare
usuallyan extra charge,It is importantto find out if they are availablefor each
specificmachineand how much they will cost. A professionalpost processoris
usuallydeliveredwith supportingdocumentationthat explainsits featuresand
all the availableswitchesto activatethem. CAMsoftwaretypicallycomes with
a set of genericpost processors,which are user-configurable. Ask if post-
developmenttrainingis available.
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Multiaxis CAD/CAM Training
Becauseof the complexityof multiaxismachining,it is not recommended that
multiaxisprogrammersbe self-taught.Trainingis a very important part of
getting the most out of the softwarepurchase,and the best training is hands-on
throughoutthe entire process.Trainingshould includeimportinggeometry,creating
toolpaths,post processing, and simulatingthesetoolpathson a virtualmachine,
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
replacethe feeling of excitementassociatedwith running a new programon a real
machine.
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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 softwarefunctionality to run its machines,it will
also be allying itself with a companythat can provideyears of experienceand
invaluable support.Considerable thoughtshouldbe givento the companybehind
the software.A well-established,reputable,companycan becomea valuableasset
and partnerto the operation.
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Throughoutthis developmentprocess,everythingis carefullydocumented.
The technicaldocumentation groupwritesHelpfiles,and trainingmanualsare
developedand tested for each product.
Conversations with peersor with companieswith whom the shopwill work are
usefulto learn what kind of softwarethey are using and why. Ask peopleif they
are happywith the localsupport,and was the softwareeasyor hardto learn?Can
filesfrom outsidesourcesbe importedand exportedeasily?Werethere any hidden
costs?Is the local resellerreDutable?Wouldthev recommendthe softwarethev are
using?
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of the software,take the time to assessthe peopleyou wouldbe workingwith if you
tr
decidedto purchasethe software.Are they enthusiastic abouttheir product?Are
they behavinglike a team, or are they shifty.disinterested
and unhelpful?
Choosinga CAD/CAMSystemForYourApplication
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Putting It AII Together
QUrZ
1.) Name three benefits to using multiaxis machining techniques,
1.
149
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3,) which of the following is the standard axis convention?
A B
1.
')
3.
5.) what are the three major building blocks of a cNc machine? (Circlethree.)
. Machinetable servo drive system . CNCcontrollercapabilities
. SpindleRPMand horsepower . CNCdrive system
. Physicalpropeftiesof the machine . Lineartable limit switches
. Chipconveyorunit
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i 6,) What are the most important physical positions of a multiaxis machine?
7.) What tools are needed to find the Machine Rotary Zero Position (MRZP)?
(Circle two.)
. level
. edgefinder
. dial indicator
. maintenance
manual
. hammer
't5t
Puttinglt All Together
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ANSWERS
1,) Why use multiaxis machining techniques?
. Multiaxismachiningtechniquesare usedto manufacture partsmoreefficiently
and accurately
by eliminatingextraset-upsand fixturing.
. Standardshortertoolingcan be used,whichresultsin the abilityto rough
moreaggressively,whileincreasingtool life.
. A moreprecisesurfacefinishcan be achievedby avoidingcontactwith the
non-spinning
deadcenterof the tool.
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Secretsof +Axis Machining
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Figure 7O-7 Multiaxis machining manufacturesparts more efficiently, increases
tool life, and producesa more precise surface finish,
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3.) What is the standard axis convention?
TABLE/TABLE
HEAD/TABLE
HEAD/HEAD
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Table/Table Multiaxis Machines
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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 supportedby a tailstock,as shownin Figure10-5.
The work piece rotates around its own axis. The pivoting head only carriesthe
weight of the tool and it handlesthe cutting pressuresgeneratedas it articulates
aroundthe work Diece.
5.) What are the three major building blocks of a CNC machine?
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its flexibilityand potentialaccuracy.The spindlemotor'storque and horsepower
further definethe characterof the physicalmachine.
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Machine Rotary Zero Position - MachineZero Positionis the intersectionof the
rotary/pivotingaxes shown in Figure 10-8. This point may be unreachableby the
machine.
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7.) What tools are needed to find the Machine Rotary Zero position
(MRzP)?
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1O.) Definition of an axis
Figure to-t7 In this examplethe spindleheadand the quill move in the same
direction,but are controlledby two separatecommands,z and W respectively.
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12,) What are the three common simultaneous multiaxis CAM toolpath
controls?
3. Tool Tip Control - Controlsthe geometryto which the tool tip is compensat-
eo.
=
TANCE
PIVOT
COMPOFFSET
LENGTH'
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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.
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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
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Finding the Pivot Distance
For Head/Table and Head/Head Machines:
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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
ltAllTogether 165
Putting
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Indexing/Rotary Positioning Work Overview
Also known as 3+2 machining,indexing/rotarypositioningwork, illustratedin
Figure 10-24, is the most basicmultiaxisconcept.The rotary/pivotingaxes are
used only for positioning,and the cutting takes placewith only the three linear
axes moving.Indexingwork is rigidand precise,It is recommended that all
possibleroughingoperationsbe performedin this rigid state.
'166
Secretsof s-AxisMachining
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Machine Simulation
Do not assumethat machinesimulationis usedonly for prove-outswith the sole
aim of findingerrorsin the code.Instead,machinesimulationshouldbe regarded
as an additionaltool to help make clean,efficient,and accurateprogramsevery
time. Machinesimulationpermitstesting of differentapproaches,differentcutting
strategieson different machines,without leavingthe desk. There is also no need to
tie down a machinefor VourDrove-outs.
In Conclusion
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Index
A Cuttnrg
ABC lineara{es.l5
Absolutecoordinatesystem.5? dircciion,l00
45.70. 103,117,138.167
strategies,
Activecoordnrabsystems,25 2'7, 57,59-61, 140 variablepitchthread,67
Acturl part zeropoint, 27
Aligneduniversc,62 D
Avoidingcollisions.45 Dedicated
multiaxismachnrcs.9, 10
Automaticlool changing,16.423 Designations of multiaxismachine
anddirections
Desiredcutterarea.engaging,l0
dcfined,l4 Dovetail effecl. 98
substitution,32 Dynanic
contol of tool axis,90,98
B robry fixtureoffset.16.27-8,36
Bal]-nosecutters,10,96,130
Bettersurfacelinishes.l0 E
Effectivcwork envelope.16
(- Engagingdesiredcutterarea,l0
CAD/CAMsystems, 3,7. 27, Extrusionmillingmachine.123
capabilities.l39
multiaxiscoDsiderations,
I 39 F
origin,60 Fanucprogritn,34
selecting,137 Fcedrate,T2
softwaredevelopmcnt, 145 dynanicchanges. 138
rcsearching,146 inversetime,74 6
tmining,l4,l optimizaiion,l3S
Calculating pivotdisiance(PD),33,37-8,169 standardlime. 74
CAM, multiaxis,139 Findingthe
Can-operated multiaxismachines,3 ccnterofrotation.21.27'8
Changeable spindleheads, 53 pivotdistance,33,36-9.l6l. l6,l
Checkingpositioning repeatibjlity.'12 XYzero,23
Circular 5'axis
73
interpolation, nachineierms,13
vectorInres,76,159
Cleancore,92
CNC nachines,39
controllers. 3, 76 positioning,T
capabilities,l3,157
drivesystems, l3
Collisionavoidance (seeAvoidingcollisioDs) G
Common misconccptions, 4, 6. 7 Gage
Complexity of rvork, 120 length(GL),36-9. 161
Computernunericalcontrol,3, 92 tower,24,163
Crashirg,I I 7 Ganrrytypehead/head 122,134
machines,
Cutpattem,79,86 94, 140,161 G codes,29.30.56, 104'106
169
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sinulntion.105 M
G 90code.29.30 Machine
G-91code.29.30 aclivccoordirrte
system.257.57 61.140,15'
Gaphicaluscrnrtel1ace,
ll6 1136,116-7,139.1,13
bxildingvirtual,64, 4, 167
busnrcsscnd,6,l,107.125
H coordinatesystems,257,56-7.61'2.1,10.
159
Head/head 18.367. ll5 6.
nrultiaxismachines. homeposidon, 16,57.60.78. 157
l2l 2. 13,t.156,i64 slstcns,25,26. 6l
localcoordinate
bridgeiype. 122
ganlry1ype,122.13,1
lasercuttingmichnre,116.135 hone positior(MRHP),l7
warcrjer miling machnre.ll6. 134 zeropoint,21,25-7,36.60 2,1 1 2, 1M
18,31.36.113,1
Headltablenrultiaxisnrachnrcs, zeroposition (MRZP).I 6 '7,21,25.21.36,
123,1.155 1 1 7 , 1 5 8 ,r96.2
aerospace, automotive 129,133
applications, simulrtion,27,63-4,98. 1036. 143.1657
millingenginchcadports,125 graphicaluserinlefaccs.I l6
nilling longrotarypafts.124 using.tl7
mdd anddic applications, 130 Machirlnlg
nuiatingheadconbinations,129 centcrconJigul"tion. 108 I l0
rotafylxble,rilthg head.12830 complexworRpicccs,5
variousconligurations,1249 cngnrccomponents.20
with longX'axis tavel. 123 profiling. ll5
Ho\vCNCmachines work,56 progrrn,29
Historyof 5 axismachining.3 routines.5. 104.138
spnd bevelgears.68
Machsimsoftwxlc,106
I
Maintenance issues.40
I n d e x n r g , 2 l , 4 4 , 5 11
, 5353.
Manualclrt.tinpur(MDl),25.1l6
lixtures,5l
Master
methods.5l
coordinalc system,60
toolpaths.49
zero,26
wirh rotar)devices.52
M-code.2l,43,60
wo*.:19.55
Milling nachineswith nvc or moreaxes.4:l
Indusrrial robots.135
\ 4 o , r e l i n2-r. ., ' 1 . u l . l l ' . I n - P l l 6 l 1 - - r )
Interpolation
159
circular,T3
Multiaxis machines.3 6. 8, 17-9,40,7,1. 124.153
linear,73
camtype.3. 140
Inversetnncleedrate, 72-4.76
dedicated,6. 9 10.21.39,52-3,110,l2l)
designilions anddirections.l5
L physicalpropeties,13.156
rorghing. 21.101.130,1402, 166
Leadandlag jn milling.100 Multiplenestnrg, 58. 61
Lnnihlions,,16
Linear
106.121,166
.txis,14 6,34.,19.74,
N
NeslingpositioDs.
25.26,56 8, 61
73
interpolation.
Newpossibilities,
11.121
Localcoordinate systems.257.56 8.61 2,117
Nunbersof parts,
120
170 Secrets
of s-Axlsl\,4achining
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Nunerical conlrol. 3 R
Rcpcating pxltcrns,l0,l
o Rotary
Old schoolsimulatifl. 104 andpivotingaxcs,32.74
One zero meihod,60 axis,16,21,33.,12.60.71.7.1, 107.i21, 156
Optimum rvork envelope.70 d c v i c c1
s ,6 , 1 8 . 2 1 . 521, l l 6 . 1 5 5
Odgin,26,60 xrdexingnechanisns,5, 54
mcchanisns. 6, 19,20.39.403. 52 3. 7l
P tool cortrolpoint(RTCP).33'4.36.l6l
Palletchargers,
40, 54, 107-8
Rotarytables,5.
8.9. 18,21,278.31 2. 130-2.
datum,17,21.27,58,158 r 5 56 .r 6 3
zeropoirt (PZP),27 8 brakes,21,.10, 52.l0,l
Plungeroughing,101-2,142 d e v i c e1s 6. ,1 89 , 2 1 , 5 12 . 7 7 .1 0 9 1. 1 6 ,1 2 61. 5 5
dynxnicfixlurcoft.\cl(RTDFO).16,27 8.36
Probesandprobing,94-5,103',1 sinsleanddual. 6, 8. 18.39.ll9
Roughnrg. 11,21,101'2,130,140'2,152,166
I'hysicalproperties
of5-axismachines, 13 Routnrcs,5.40,42, 1045
Pivot
distance.33 S
point,379 Secondrotart table,18
Pivonngspindleheads,18,32-6,38. 124.156.lbo Selecfirgnachnlcs,I l9
Pockct nrilling.5.86,l2l, ll7 9 Selectingsoftware.137
Positioning$ork. 5, 7, 8. 13,20-l, 26. 42,49,52, Stullrlaftrn,
19,27,47.63 4.98.10317.I38,1667
r 5 9r,6 6
cutlingmotions,10,71
processing,3.4.8.34,40,76 8. 103-6,138, millingte.hniques.2l
1 4 37 , 1 5 9 r, 6 6 muhiaxistoolpathconirols,79,101,152.161
processor,3,4, 8,39,40,769. 10zl6, I16,138. toolpaths. 5.48.65.78. 103,105,107.l2l
1 4 3 1, 4 7 , 1 5 9 Special-puryosesoftlvare,137
Probingroutines.1045 Spindle heads.changeable. 31.53
Program Spil"l splines,99
nnnurleditnrg. 104
subloutines. 9, ,13-4. 10.1 Standard multiaxisnomenclature.
15
zcroposition (PZP).l6 8,25.32.117.158-9.162 Slock(natcrial)option1.47.102
-
P r o g r d m n r i l gq...118 . 2 4/ 5
. 6 .5 4 . 6 ) . l . l 0 : . rccognition,1,12
105.138,144.147 Subroutines.3.43. 104
.onsiderations, 46 Surlacelinishes.better,5,10
languages,3
limitrtions.46 origin.60
view,27
a
Qucstbnsandanswers, 46. I 44. I 41. 119 T
physicalpositions,151,157 Txblc/lxblc multiaxis machnrcs,
l8 9.24.I10.125,
standard
axisconvention. 150.154 1 3 2 1, 5 5 . 1 6 2
wjth port-nillingaftachment, 125
'171
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honnionandrock andro11Iixtules,71. 111,I32
variousapplications. 133
3D surfacing toolpaths, 5
Tiltingspindleheads,31
Tombstone lixtures,6, 40, 58-9,108
Tool
axiscontrol,79,86,89,91-2,98, 139,l4l, 161,
lengrhoffsets,18, 24, I 17
lists,46,140,145
for lathes.138
simultaneous,65
planewith odgin,27
tip control,79,90-91,l4l
Tradeshows,146
Training,144
2 + 3 positioning,49
U
UsingmotionsXYZ andC,67
Unlockedrotary drives, 11
U\r!V linear axes,15
v
Vericutsoftware,1,95, 106,116-117
Verilication system,27, 104
Visitingsoftwarecompanies, 1, 146-7
Virtualmachine,103,105
building,l06
components andmodels,107
configudngfor simulation,105
kinematiccomponenttlee, 107
skeleton,106
w
wire franes,79,103,139-40
Worldzero,26,60
x
7,74
XYZ linearaxes,15.32,66
z
Zeroingthe indicator,22
Zeroposition, 17,21,117.158,162
Z-Maximum,37
Z-Minimum,38
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Virtual MachiningCD
Allthe imageson this CD, includingthe virtualmachines,were modeledusinglvlastercam@
(CNCSoftware,Inc.). The virtualmachineswere broughtto life usingthe machinesimulation
capabilitiesof l4achsim (lYoduleworks)and VERICUT6(CGTech).
Installation
The enclosedCD should run automaticallywhen inserted into a CD-ROlqdrive. if the auto-
run feature does not work. please use File I\4anagerto navigateto the CD. Find the file called
Index.htmland dolrble-click it.
System Requirements
The CD was built to run ootimallvon a PCwith:
. WindowsXP or Vista
. Internet Explorer(Version7) or higher
. 1024x 768 resolution(or higher)
. Adobe@ Acrobat Reader@ installed. (Go to http://www.adobe.com/downloads/to install a
free version,)
. AppleQuickTimeplug-ininstalled.(Go to hftp://www.apple.com/quicktime to installa
free version,)
. If you installthis cD on your hard disk.you will need650 l4Bfree space.
. Real Machining videos - watch a real s-axis machine pefform several different
multiaxiscuttingroutineson complexsimulLaneous 5-axisparts,
. Printable PDF Files - Quick Referenceguidesfor the most important aspectsof setting
up a s-axismachineand commonmultiaxisconceptsall availableas easyprint-outs,
Technical Questions:
Pleaseemailyour questionsto info@industrialpress,com
or to the authorat
Or visit www.5axissecrets.wordpress.com
karlo.apro@gmail.com. and go to the link for FAQS.
www.engreferencebooks.com