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Multi Axis MachiningMulti Axis Machining
Matt CulenMatt CulenJon LinardJon LinardAmy MoiseAmy Moise
Karsten TessarzikKarsten Tessarzik
BackgroundBackground
Standard 3-axis machining Standard 3-axis machining allows the spindle or workpiece allows the spindle or workpiece to move in the x-, y-, and z-to move in the x-, y-, and z-directionsdirections
Multi-axis machining allows the Multi-axis machining allows the spindle or workpiece to rotate spindle or workpiece to rotate about these axesabout these axes
BackgroundBackground
3-axis Milling3-axis Milling Appears as both manual and CNCAppears as both manual and CNC
5 or more axis combine milling and turning5 or more axis combine milling and turning Appears as NC and CNCAppears as NC and CNC Can perform milling, drilling, threading, and Can perform milling, drilling, threading, and
boring all in one machine with high accuracyboring all in one machine with high accuracy 6th-side machining6th-side machining
History of Multi Axis MachiningHistory of Multi Axis Machining
Industrial revolution spawned the creation of Industrial revolution spawned the creation of metal machiningmetal machining Need to create and finish parts of machineryNeed to create and finish parts of machinery
Mostly turning and boringMostly turning and boring Milling machine existed but not as widely used until Milling machine existed but not as widely used until
18501850 Computerization Computerization
First NC – fixed operationsFirst NC – fixed operations Later CNC – changeable parametersLater CNC – changeable parameters CAM softwareCAM software
Multi Axis MachinesMulti Axis Machines
Allow machining of Allow machining of complex parts in a single complex parts in a single setupsetup
Shorter Cutters allow Shorter Cutters allow better surface finishesbetter surface finishes
Can perform functions of Can perform functions of lathes toolathes too Boring, drilling, milling, Boring, drilling, milling,
tapping, and turningtapping, and turning Utilizes two tilting axesUtilizes two tilting axes
Aerospace IndustryAerospace Industry
Short lead-time workShort lead-time work Just in Time deliveryJust in Time delivery Reduces InventoryReduces Inventory Enables quick reworkingEnables quick reworking
Elaborate parts can be Elaborate parts can be more easily duplicatedmore easily duplicated Consistent Physical Consistent Physical
propertiesproperties Better tolerances for detailBetter tolerances for detail Impellers, Turbines, etc.Impellers, Turbines, etc.
Mold Making IndustryMold Making Industry
Allows complex molds Allows complex molds to be made quickly and to be made quickly and efficientlyefficiently
Eliminates post-Eliminates post-machiningmachining No polishingNo polishing No additional machiningNo additional machining
Reduces labor costsReduces labor costs
Other IndustriesOther Industries
Expanded use to other Expanded use to other industries, i.e. automotive, industries, i.e. automotive, medicalmedical
Why?Why? Improvements in HandlingImprovements in Handling reduced Cutting Timereduced Cutting Time Increased production Increased production
capabilitiescapabilities Fewer Setups per partFewer Setups per part No need to manually No need to manually
change toolschange tools Adaptable to a variety of Adaptable to a variety of
different industriesdifferent industries
EconomicsEconomics Traditional MachinesTraditional Machines
such as those in the such as those in the Engineering Processes LabEngineering Processes Lab
Cost: approximately Cost: approximately $10,000.$10,000.
Only Have 2 or 3 axis Only Have 2 or 3 axis control, limited functionalitycontrol, limited functionality
Machining Centers Machining Centers more utility, greater more utility, greater
productivity and capacityproductivity and capacity higher pricehigher price
Initial Investment of $250 Initial Investment of $250 thousand to millionsthousand to millions
Tilt/Rotary TablesTilt/Rotary Tables
Can replace table of old Can replace table of old three axis machine to three axis machine to achieve 5 axis productionachieve 5 axis production Less expensive alternativeLess expensive alternative Smaller work surface limits Smaller work surface limits
part sizepart size
Unsuitable for larger partsUnsuitable for larger parts Cannot be secured to work Cannot be secured to work
table adequatelytable adequately Cannot perform heavy Cannot perform heavy
cutting operationscutting operations
Spindle Head AttachmentSpindle Head Attachment
Basic Spindle can be Basic Spindle can be replaced with a CNC replaced with a CNC spindle head.spindle head. Can weigh about 150 lbsCan weigh about 150 lbs Allows 5 Axis MovementAllows 5 Axis Movement
Does not provide as much Does not provide as much freedom of movement as a freedom of movement as a new 5 axis spindle new 5 axis spindle machining centermachining center
Multi Axis MachinesMulti Axis Machines
Most are larger, more Most are larger, more expensive modelsexpensive models Accurate, PowerfulAccurate, Powerful Run from $500,000 to $1.5 Run from $500,000 to $1.5
Million Million
Low end runs about Low end runs about $250,000$250,000
Machines can have Machines can have multiple spindles to work on multiple spindles to work on different parts and different parts and operationsoperations
Machining CentersMachining Centers
Typically 5 or more AxisTypically 5 or more Axis Allow wider variety of toolingAllow wider variety of tooling 12 to 180 different tools12 to 180 different tools
Computer Numerically Computer Numerically ControlledControlled
Sizes can vary depending Sizes can vary depending on features and coston features and cost
Offer advanced production Offer advanced production capabilities to smaller capabilities to smaller companiescompanies
Current Machine ExampleCurrent Machine Example
RM5 VRM5 V 5 Axis Machining Center5 Axis Machining Center 30 Tool heads30 Tool heads Pallet System for Autonomous Pallet System for Autonomous
operationoperation Oil Mist LubricatedOil Mist Lubricated
AccurateAccurate Laser Calibrated AxesLaser Calibrated Axes Laser Tool Measuring and Laser Tool Measuring and
Breakage DetectorBreakage Detector
Computer Numerically Computer Numerically ControlledControlled
Multi Axis SoftwareMulti Axis Software Tooling is running in Tooling is running in
multiple axes multiple axes simultaneouslysimultaneously
Simulation ProgramsSimulation Programs Collision Avoidance Collision Avoidance
ProgramsPrograms Current ExamplesCurrent Examples
Delcam PowerMillDelcam PowerMill GibbsCAMGibbsCAM MasterCam MasterCam
Reduction in wasted time Reduction in wasted time by establishing most by establishing most efficient machining routineefficient machining routine
Continuous Versus PositionalContinuous Versus Positional
PositionalPositional Series of Discrete Series of Discrete
OperationsOperations Time benefits because of Time benefits because of
single setupsingle setup ContinuousContinuous
Tool path along complex Tool path along complex surfacessurfaces
Ideal for profiling parts Ideal for profiling parts and contouring surfacesand contouring surfaces
Parametric ProgrammingParametric Programming
Support of logical Support of logical commandscommands Creates programming Creates programming
language similar to BASIClanguage similar to BASIC Logic can be used to create Logic can be used to create
entire product linesentire product lines
Custom Machining CyclesCustom Machining Cycles Subroutines such as bolt Subroutines such as bolt
circles and fixturescircles and fixtures Allow programs to be easily Allow programs to be easily
made and modifiedmade and modified
7 axis machining7 axis machining
Combination of 5-axis with two indexers addedCombination of 5-axis with two indexers added Applications in the Aerospace industryApplications in the Aerospace industry Eliminates need to remove and re-set Eliminates need to remove and re-set
workpiecesworkpieces Pieces do not have to be finished by handPieces do not have to be finished by hand Overall better quality and more efficientOverall better quality and more efficient
Advantages Summary Advantages Summary Creation of complex contours Creation of complex contours
and parts and parts Simultaneous movement and Simultaneous movement and
feed along all 5-axesfeed along all 5-axes Parts don’t have to be castParts don’t have to be cast Reduced lead times Reduced lead times Higher accuracy attainableHigher accuracy attainable
Allows machining on all 5 sides Allows machining on all 5 sides of a partof a part Surface can be machined at Surface can be machined at
any angleany angle Reduces time and cost of Reduces time and cost of
producing fixturesproducing fixtures Reduces inaccuracy in Reduces inaccuracy in
alignment due to multiple set alignment due to multiple set upsups
Advantages SummaryAdvantages Summary Allows tool to access points on Allows tool to access points on
the work piece that would not the work piece that would not normally be possible without an normally be possible without an additional set-up.additional set-up.
Part production can be Part production can be simplified by tilting and indexing simplified by tilting and indexing with two rotary axes and with two rotary axes and machining in the other threemachining in the other three
Shorter cutters can be used Shorter cutters can be used because the tool can be lowered because the tool can be lowered toward the work piece and toward the work piece and oriented toward the surfaceoriented toward the surface Lower cutter loads, higher Lower cutter loads, higher
cutting speeds, longer tool lifecutting speeds, longer tool life Decreased vibration, better Decreased vibration, better
surface finishsurface finish
DisadvantagesDisadvantages
Large Initial investmentLarge Initial investment Increased cost of toolingIncreased cost of tooling Increased complexityIncreased complexity Increased volume of codeIncreased volume of code Highly skilled programmer Highly skilled programmer
or more sophisticated or more sophisticated software required to software required to generate tool pathsgenerate tool paths
Turbocam Automated Turbocam Automated Production Systems (TAPS)Production Systems (TAPS)
Implemented 5-axis Implemented 5-axis machining to produce machining to produce automotive turbocharger automotive turbocharger impellersimpellers Reduced production costs by Reduced production costs by
90% compared to previous 90% compared to previous machining methodsmachining methods
Cost competitive with cast Cost competitive with cast impellersimpellers
Tolerances achievable Tolerances achievable through machining are five through machining are five to ten times better than to ten times better than cast unitscast units Increased efficiencyIncreased efficiency Superior engine performanceSuperior engine performance
“A Compelling Pick for Impeller Production.” Modern Application News September 2006: 40.9
VideoVideo
ResourcesResources
“ “A Compelling Pick for Impeller Production.” A Compelling Pick for Impeller Production.” Modern Application NewsModern Application News September 2006: 40.9September 2006: 40.9
““Methods Machine Tools Fanuc Robodrill 5-Axis Impeller Blade”Methods Machine Tools Fanuc Robodrill 5-Axis Impeller Blade”
http://youtube.com/watch?v=fXWMDN5amzEhttp://youtube.com/watch?v=fXWMDN5amzE
Waurzyniak, Patrick. “Five Axis Programming.” Waurzyniak, Patrick. “Five Axis Programming.” Manufacturing EngineeringManufacturing Engineering April 2007.April 2007.
Kennedy, Bill. “Combined Efforts. ” Kennedy, Bill. “Combined Efforts. ” Cutting Tool EngineeringCutting Tool Engineering May 2006: 58.5 May 2006: 58.5
““Reasons To Use 5-Axis Machining.” Reasons To Use 5-Axis Machining.” MMS Online MMS Online http://www.mmsonline.com/articles/090407a.htmlhttp://www.mmsonline.com/articles/090407a.html