© UGS Corp. 2004. All rights reserved.

Multi-Axis Machining Concept

2

Key Elements

Machine

Various type of configurations

Choose the right configuration for the right job

Controller

Most well-known controllers provide excellent features

Every contoller has its own strength in specific area

CAM System

Not every CAM system is equal

NX is among one of the best

Knowledgable and Experienced People

People make things different

3

Machine Type and Configuration

C Frame

Gantry

Dual Rotary Tables

Dual Swiveling Heads

Table Head

Non-Orthographics

Turn-Mill

Hexapods

4

Kinematic Relative Spacing

5

X

Z

C-Frame Table-Head Configuration

Work Piece Table

Light to medium weight work piece

Minimize work piece movement

Minimize axes stack up

Easy work piece setup

Good visiblility

Spindle Head

Extra X movement required when spindle swiveling about Y axis

The longer the tool, the more extra X movement required

Tool length matter

6

Dual-Table

Rotary Tables

Lightweight work piece

Work piece stack up

Reduce stiffness

Extra linear movement on both X, Y, Z

Work piece setup consideration

Linear axis traverse limit

Collision between moving components

Tool axis always parallel to linear axis

Good for tool axis moving back and forth intensively operations, such as drilling and tapping

B

C

Non-OrthographicB 45° between Y and Z

Non-OrthographicB 45° between Y and Z

X

Z

7

Dual-Head

Large size and heavy work piece

Easy work piece setup

Tool length matter

8

Gantry Dual-Head 3 Spindles

Hugh size work piece, heavy duty

Machine three parts at the same time

Tool length matter

9

Rotary Table

Flexible Rotary axis stack up on work table

Accurate installation and setup must be ensured every time

Beware of extra space needed for attached moving control unit

Rotary table manufacturer not necessary the machine manufacturer, need to understand how rotary axis synchronize with linear axis

10

Turn Mill

Eliminate multi-setup for turning and milling

Mainly for turning

Milling operation might not as efficient as milling machine

Might not suitable for part that has large percentage of milling operation

Turning TimeTurning Time

Setup TimeSetup Time

Milling TimeMilling Time

Small % of milling operationSmall % of milling operation

Large % of milling operationLarge % of milling operation

Turn MillTurn Mill

Turn + MillTurn + Mill

Turn MillTurn Mill

Turn + MillTurn + Mill

11

Hexapods

6 DOF

Commercial acceptance has been slow, long way to go

12

Right Tool for The Job

13

Multi-Axis Machining

Fixed-Axis Machining means tool axis or workpiece orientation is fixed and will not change during the machine operation.

Multi-Axis Machining implies at least one rotary axis is involed, however …

Utilizing a multi-axis machine not necessarily mean the rotary axis must be moving simultaneously with other axis

In many cases the rotary axis position the part or tool axis to a fixed orientation, then perform a Fixed-Axis Machining

Most of machinery parts Engine housing, gear-box …

Choose the most appropiate machining strategy

Ask why one strategy is better than the other. For example: The main goal of rough cut is to remove large amout

of material in minimum time. We might ask why multi-axis for roughing is better than fixed-axis. If the answer doesn’t fit the goal, we might need to revise the strategy

14© UGS Corp. 2004. All rights reserved.

FA Machining with MA Machines

15

Plannar Milling

Specify tool axis orientation

Circular Output

Non-swivelling head usually has no problem handling circular interpolation

Swivelling head

Depends on controller and machine

Might need to output linear motion only

Post-processor handle the circular to linear conversion

Tolerance matter

16

Drilling

Tool Axis Options

+ZM Axis

Specify Vector

Normal to Part Surface

Use Arc Axis

Canned Cycle

Non-Swivelling head usually has no problem handling canned cycle

Swivelling head

Depends on controller and machine

Might need to output point to point

Post-processor handle the canned cycle to points conversion process

17

Define Working Plane with Heidenhain

18

Define Working Plane with Siemens 840D

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Main MCS

Define Main MCS

Customize MCS object, add CS Purpose

Set CS Purpose as “Main”

20

Local MCS

Create Local MCS under Main MCS

Customize Local MCS, add CS Purpose and Special Output, Set to Local and None

21

MOM_set_csys Event

22© UGS Corp. 2004. All rights reserved.