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