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A Simplified Approach

to Complex 5-Axis
Milling
Ann Mazakas
DP Technology Corp.
You will learn:
5-axis machine configurations
The traditional approach to 5-axis
programming
A simplified approach to 5-axis
programming
The four simple steps to creating
5-axis programs
5-Axis Machine
Configurations
Two additional rotary axes are located
on the table, on the head, or a
combination of the two
The CAM system must support the
kinematics of any 5-axis machine
Properly defining the motion of the
machine in the CAM system is critical to
a good calculation of the tool path
2 Rotary Axes on the
Table
Mill-Turn Mill
1 Rotary Axis on the
Table, 1 on the Head
Mill-Turn Mill
2 Rotary Axes on the
Head
Mill
3 Rotary Axes
Some machines have
more than 2 rotary axes
These machines offer
maximum flexibility in the
positioning of the tool
The user decides the fixed
position of one rotary axis
The system controls the
behavior of the other two
axes
2 Rotary Axes on the
Tool, 1 on the Table
Mill-Turn Mill
The Traditional
Approach to 5-axis
Programming
Create a dozen or more functions
for very specific machining
strategies, especially finishing
routines
Expect the CNC programmer to
learn and remember all these
functions
A Simplified Approach
Follow the same logic that
machinists use when deciding how
to program a part
Use a single function that is easy
to learn and easy to use, yet is
powerful and error-proof
Composite 5-Axis
Function
One function with:
6 machining patterns

+ 4 tool orientations

= 24 unique strategies
Composite Advantages
The machining pattern and tool
orientation are defined separately
New patterns and orientations can
be easily added or removed in the
future
The two modules are fully tested to
work separately and together for a
more reliable software
Unlimited Creativity
Create your own customized tool
path
Try different techniques without
using multiple functions
Try different tool orientations
before deciding on the perfect cut
4 Simple Steps
Any 5-axis machining function, no
matter how complex, can be simplified
into 4 steps.
1.Define the area to machine
2.Define the shape of the tool path
3.Define the orientation of the tool axis
as it travels along the tool path
4.Define the links within the tool path
and between operations
Step 1: Define the area
to machine
Select surfaces to
machine (green) and
surfaces to avoid (red)
Save the selection as a
feature
Step 1: continued
Multiple features can be
created on a single model
Add or remove surfaces
from a feature at any time
The biggest benefit?
Editing a feature
automatically updates the
associated tool path
Step 2: Define the shape
of the tool path
Choose from a
variety of options:
Parametric
Spiral
Planar
Offset (concentric)
Step 2: patterns
continued
A dynamic interface shows only whats needed.
Step 2: patterns
continued
Parametric tool path follows
the flow lines of the
surfaces
2 types of parametric tool
path:
Use a surface on the part
Project the flow lines from a
separate surface
Step 2: patterns
continued
Parametric Spiral tool
path projects a
continuous spiral pattern
onto the machining area
This pattern requires a
closed shape
Step 2: patterns
continued
A Note about Projection Surfaces
Create a single surface from
multiple faces on a solid
Flow lines are smooth and
continuous
Automatically
cover
openings
Step 2: patterns
continued
Planar tool path creates a
uniformly spaced step over
based on a set of calculated
planes that slice through the
part
2 types of planar tool path:
Along a Linear path
Along a Curved path
Step 2: patterns
continued
Boundary offset tool
path creates a
concentric pattern
from the outside in or
inside out
Step 3: Define the
orientation of the tool
axis
Choose from a variety of options:
Normal to surface
Through a point
From a fixed vector
From a profile

Plus:
Control the forward and sideways tilt of the tool
Lock an axis for 4+1 machining
Avoid collisions with Auto Tilt
Step 3: tool axis
continued
Perpendicular to
Surface: Keeps the
tool axis perpendicular
to a drive surface
The drive surface can
be on the part or a
projection surface
Step 3: tool axis
continued
Through a Point: The tool
axis is forced to pass
through a specified fixed
point
This strategy works well
on internal surfaces with a
restricted opening
For convex surfaces, the
tool can go Toward a point
Step 3: tool axis
continued
From a Fixed Vector: The
tool axis keeps a fixed
direction
This strategy creates tool
path similar to 3-axis
except that the user
controls the direction of
the tool vector
Step 3: tool axis
continued
From a Profile: The tool
axis is forced to pass
through the points of a
3D curve
This strategy works
extremely well for
machining in a channel
or areas where the tool
could collide with a wall
Step 3: tool axis
continued
Tilt the tool to move the contact point of the
tool in relation to the part
In-line Angle: Controls the tilt of the tool in the
direction of the cut for a pulling cut
Cross Angle: Controls the side tilt of the tool
Step 3: tool axis
continued
Moving the contact point on the tool
can prevent the center of the tool
from removing any material for better
efficiency and a better tool life
With In-line angle set to 0, the tool
contact point with the blade edge is
the tool center
With a 20 degree in-line angle, the
tool front end is in contact with the
blade.
Step 3: tool axis
continued
Adding a cross angle lets you
tilt the tool sideways to avoid
collisions
It also lets you move the
contact point on the tool
away from the center of the
tool
Step 3: tool axis
continued
The orientation of the tool
axis can be limited or fixed
Limit Angle: The tool axis
orientation will never
exceed the minimum and
maximum angle with
respect to the specified
axis (X, Y or Z)
Fixed Angle: The tool axis
keeps a fixed slope with
respect to the specified
axis (X, Y or Z)
Step 3: tool axis
Auto Tilt continued
Avoid collisions
Uses the selected tool axis orientation until a collision is detected
Then uses rule-based alternative tool orientations to adjust the
tool axis
Auto Tilt = On
Rule = Tilt around tool axis with
Auto Tilt = Off maximum 30 angle
Step 4: Define the links
A prioritized list of
preferences for:
Approaches to the part
after a rapid move
Feed links to connect
gaps between passes
and between depths
Rapid links for tool
repositioning
Step 4: links continued
All links provide smooth
transitions
All links are calculated
for the best results for
the machine
The user only needs to
define the maximum gap
distance for feed
movements
Step 4: links continued
Links are applied in priority order
If the first link in the list is not possible, the
system uses the next linking technique and
so on
Geometry for 5-axis
milling
The geometry required for 5-axis milling can
take up to half your time:
Additional surfaces or fake surfaces
Drive surfaces for parametric machining
Curves or points to control the tool axis
Make sure the CAM system supports this
type of specialized geometry
Conclusion
A modular approach to CAM software:
Makes the software easily adaptable to
future advances in machine tool technology
Provides better reliability because each
module is fully tested
Allows for faster responses to market
changes and user requests for
enhancements
Makes the software easier to use
Ann Mazakas
DP Technology
805.388.6000 x143
Ann.mazakas@dptechnology.com

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