Matt Culen Jon Linard Amy Moise Karsten Tessarzik Multi Axis Machining Matt Culen Jon Linard Amy Moise Karsten Tessarzik

Background Standard 3-axis machining allows the spindle or workpiece to move in the x-, y-, and z-directions Multi-axis machining allows the spindle or workpiece to rotate about these axes

Background 3-axis Milling 5 or more axis combine milling and turning Appears as both manual and CNC 5 or more axis combine milling and turning Appears as NC and CNC Can perform milling, drilling, threading, and boring all in one machine with high accuracy 6th-side machining

History of Multi Axis Machining Industrial revolution spawned the creation of metal machining Need to create and finish parts of machinery Mostly turning and boring Milling machine existed but not as widely used until 1850 Computerization First NC – fixed operations Later CNC – changeable parameters CAM software

Multi Axis Machines Allow machining of complex parts in a single setup Shorter Cutters allow better surface finishes Can perform functions of lathes too Boring, drilling, milling, tapping, and turning Utilizes two tilting axes

Aerospace Industry Short lead-time work Just in Time delivery Reduces Inventory Enables quick reworking Elaborate parts can be more easily duplicated Consistent Physical properties Better tolerances for detail Impellers, Turbines, etc.

Mold Making Industry Allows complex molds to be made quickly and efficiently Eliminates post-machining No polishing No additional machining Reduces labor costs

Other Industries Expanded use to other industries, i.e. automotive, medical Why? Improvements in Handling reduced Cutting Time Increased production capabilities Fewer Setups per part No need to manually change tools Adaptable to a variety of different industries

Economics Traditional Machines Machining Centers such as those in the Engineering Processes Lab Cost: approximately $10,000. Only Have 2 or 3 axis control, limited functionality Machining Centers more utility, greater productivity and capacity higher price Initial Investment of $250 thousand to millions

Tilt/Rotary Tables Can replace table of old three axis machine to achieve 5 axis production Less expensive alternative Smaller work surface limits part size Unsuitable for larger parts Cannot be secured to work table adequately Cannot perform heavy cutting operations

Spindle Head Attachment Basic Spindle can be replaced with a CNC spindle head. Can weigh about 150 lbs Allows 5 Axis Movement Does not provide as much freedom of movement as a new 5 axis spindle machining center

Multi Axis Machines Most are larger, more expensive models Accurate, Powerful Run from $500,000 to $1.5 Million Low end runs about $250,000 Machines can have multiple spindles to work on different parts and operations

Machining Centers Typically 5 or more Axis Allow wider variety of tooling 12 to 180 different tools Computer Numerically Controlled Sizes can vary depending on features and cost Offer advanced production capabilities to smaller companies

Current Machine Example RM5 V 5 Axis Machining Center 30 Tool heads Pallet System for Autonomous operation Oil Mist Lubricated Accurate Laser Calibrated Axes Laser Tool Measuring and Breakage Detector Computer Numerically Controlled

Multi Axis Software Tooling is running in multiple axes simultaneously Simulation Programs Collision Avoidance Programs Current Examples Delcam PowerMill GibbsCAM MasterCam Reduction in wasted time by establishing most efficient machining routine

Continuous Versus Positional Series of Discrete Operations Time benefits because of single setup Continuous Tool path along complex surfaces Ideal for profiling parts and contouring surfaces

Parametric Programming Support of logical commands Creates programming language similar to BASIC Logic can be used to create entire product lines Custom Machining Cycles Subroutines such as bolt circles and fixtures Allow programs to be easily made and modified

7 axis machining Combination of 5-axis with two indexers added Applications in the Aerospace industry Eliminates need to remove and re-set workpieces Pieces do not have to be finished by hand Overall better quality and more efficient

Advantages Summary Creation of complex contours and parts Simultaneous movement and feed along all 5-axes Parts don’t have to be cast Reduced lead times Higher accuracy attainable Allows machining on all 5 sides of a part Surface can be machined at any angle Reduces time and cost of producing fixtures Reduces inaccuracy in alignment due to multiple set ups

Advantages Summary Allows tool to access points on the work piece that would not normally be possible without an additional set-up. Part production can be simplified by tilting and indexing with two rotary axes and machining in the other three Shorter cutters can be used because the tool can be lowered toward the work piece and oriented toward the surface Lower cutter loads, higher cutting speeds, longer tool life Decreased vibration, better surface finish

Disadvantages Large Initial investment Increased cost of tooling Increased complexity Increased volume of code Highly skilled programmer or more sophisticated software required to generate tool paths

Turbocam Automated Production Systems (TAPS) Implemented 5-axis machining to produce automotive turbocharger impellers Reduced production costs by 90% compared to previous machining methods Cost competitive with cast impellers Tolerances achievable through machining are five to ten times better than cast units Increased efficiency Superior engine performance “A Compelling Pick for Impeller Production.” Modern Application News September 2006: 40.9

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Resources “A Compelling Pick for Impeller Production.” Modern Application News September 2006: 40.9 “Methods Machine Tools Fanuc Robodrill 5-Axis Impeller Blade” http://youtube.com/watch?v=fXWMDN5amzE Waurzyniak, Patrick. “Five Axis Programming.” Manufacturing Engineering April 2007. Kennedy, Bill. “Combined Efforts. ” Cutting Tool Engineering May 2006: 58.5 “Reasons To Use 5-Axis Machining.” MMS Online http://www.mmsonline.com/articles/090407a.html