1. © 2011 Autodesk Simplified 5-Axis Machining Ann Mazakas Manager of Technical Communications | DP Technology Corp.

2. © 2011 Autodesk Class Summary This class introduces an approach to CAM functionality that simplifies the methodology of multi-axis machining into one unique CAM function called a Composite function. By following the same logic that machinists use when deciding how to program a part, the Composite function is familiar and easy to understand, yet flexible and powerful enough to exploit the full capabilities of advanced machine tools today and in the future.

3. © 2011 Autodesk Learning Objectives At the end of this class, you will be able to:  Understand how 5-axis machines work  Exploit the capabilities of multi-axis machines without struggling to learn multiple CAM functions  Describe a simplified 4-step CAM methodology for multi-axis machining  Explain how a single milling function can combine a range of popular toolpath definitions  Maintain complete control over the tool axis orientation during the cut

4. © 2011 Autodesk What is 5-axis machining?

5. © 2011 Autodesk 5-Axis is …  2 rotary axes + 3 linear axes  Standard X, Y, and Z  Rotary A, B, or C  Affordable  Versatile

6. © 2011 Autodesk How is 5-axis used?  Machine complex shapes that cannot be achieved with standard methods  More commonly used to execute 3-axis machining with rotary positioning moves between operations

7. © 2011 Autodesk Table/TableTable/Tool (Mill)Table/Tool (Mill-Turn)Tool/Tool Both rotary axes are in the table One rotary axis is in the table, one in the tool The rotary axis is in the turning spindle, the other in the tool Both rotary axes are in the tool 5- Axis Machine Configurations

8. © 2011 Autodesk Rotary axes can …  Move simultaneously with the linear axes  Great for sculpted surfaces and aerodynamic shapes  Rotate the part/tool into position before cutting starts (3+2)  The most practical application for many shops  Be locked individually so that only one axis can rotate during the cut (4+1)  Great for mill-turn machines

9. © 2011 Autodesk Benefits of 5-axis machining  Save time and money  Reduce part setups  Reduce part handling  Improve accuracy  Eliminate repositioning errors  Improve customer service  Faster, more accurate output  Expand your market  Add flexibility

10. © 2011 Autodesk Exploiting the Capabilities of a 5-axis Machine

11. © 2011 Autodesk Challenges of 5-axis  Exploit the additional axes of motion  Coordinate the motion of multiple axes  Avoid collisions  Stay within the limits of the machine

12. © 2011 Autodesk How can a CAM system help?  Follow the same logic as machinists  Make simulation realistic  Provide reliable post processing

13. © 2011 Autodesk A Simplified Approach  Create 1 CAM function  Build that function from interlocking modules  Build intelligence into the interface

14. © 2011 Autodesk Simplified CAM for 5-Axis

15. © 2011 Autodesk 4-Step Process 1. Define the area to machine 2. Define the shape of the tool path 3. Define the orientation of the tool axis 4. Define the linking strategy

16. © 2011 Autodesk Step 1 - Define the area to machine  Specialized feature: FreeForm  One feature = one selection  One model = multiple features  Editable  Associative tool path

17. © 2011 Autodesk Show Me – Feature Creation  Select faces to machine  Use propagation for fast and easy selection  Select faces to avoid

18. © 2011 Autodesk Step 2 - Define the shape of the tool path  Parametric  Project Parametric  Project Spiral  Parallel Planes  Planes with Spine Curve  Contour Offset

19. © 2011 Autodesk Parametric toolpath  Follows the parametric curves of the surface  Two methods:  Follow the flow lines of the model  Follow the flow lines of a projected surface  Knitted surface  Corrects misaligned faces  Allows parametric machining over multiple faces

20. © 2011 Autodesk Spiral toolpath  Continuous uninterrupted cut  Projects the flowlines of a separate surface

21. © 2011 Autodesk Planar toolpath  Evenly spaced passes along the model  Two methods:  Along a straight vector  Along a curve

22. © 2011 Autodesk Offset toolpath  Shape based on the boundary of the area to machine  Two methods:  Outside in  Inside out

23. © 2011 Autodesk Other points to consider  Control the distribution of points  Increase precision  Prevent ‘jerk’

24. © 2011 Autodesk Step 3 – Define the orientation of the tool axis  Normal to Model  Perpendicular to Drive Surface  Through Point  From Profile  From Fixed Vector

25. © 2011 Autodesk Show Me – Normal to Model  The surface normals on the model control the tool axis

26. © 2011 Autodesk Show Me – Perpendicular to Drive Surface  A separate surface controls the tool axis

27. © 2011 Autodesk Show Me – Through Point  Control the tool axis with a fixed point  Used for shank containment

28. © 2011 Autodesk Show Me – From Profile  Control the tool axis with a curve  Two options:  Through curve  Toward curve

29. © 2011 Autodesk Show Me – From Fixed Vector  Lock the tool axis along a vector  3+2 machining

30. © 2011 Autodesk Controlling the tilt of the tool  Tilt the tool:  Forward or backward (In-line angle)  To the right or left (Cross angle)  Move the contact point of the tool

31. © 2011 Autodesk Axis Limits  Limit rotation within a range of angles  Lock an axis for 4+1

32. © 2011 Autodesk Show Me – Auto Tilt  Avoid collisions  Automatically adjust the tool axis Auto Tilt = OffAuto Tilt = On

33. © 2011 Autodesk Step 4 – Define the linking strategy  Approaches  Feed Links  Rapid Links  Feed versus Rapid

34. © 2011 Autodesk Show Me – Prioritized Lists  Choose preferences  Let the system determine what’s possible

35. © 2011 Autodesk The 4-Step Review 1. Define the area to machine 2. Define the machining pattern 3. Define the tool axis orientation 4. Define the links

36. © 2011 Autodesk Unlimited creativity  Programming your way  Full 5-axis  4+1  3+2 6 machining patterns5 orientation strategies + = 30 unique machining strategies

37. © 2011 Autodesk Summary  Now you know:  How 5-axis machines work and the benefits of 5-axis  How a single CAM function can simplify the programming process  Popular machining patterns for 5-axis  How to control the tool axis during the cut Questions? Please contact me at ann.mazakas@dptechnology.com

38. © 2011 Autodesk Autodesk, AutoCAD* [*if/when mentioned in the pertinent material, followed by an alphabetical list of all other trademarks mentioned in the material] are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and services offerings, and specifications and pricing at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. © 2011 Autodesk, Inc. All rights reserved.