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

2. 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

3. 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

4. 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

5. 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

6. 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.

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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. Video

24. Resources
“A Compelling Pick for Impeller Production.” Modern Application News September 2006: 40.9
“Methods Machine Tools Fanuc Robodrill 5-Axis Impeller Blade”
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