CAM systems have a diverse selection of toolpath strategies to choose from, and each has an appropriate place in 5-axis machining. But just like everything else in multi-axis programming, the programmer's experience and the actual machine configuration will play a big part in the selection of the suitable toolpath for a particular application.
If you asked 10 different 5-axis programmers to program the same single part, you would most likely get 10 different machining strategies. Depending on experience, machine configuration, CAM software, tooling, workholding, and a myriad of other criteria, everyone sees the path they need to travel just a little bit differently. But they all lead to the same place: a successfully completed part. This article will be part one in a multi-part series about 5-axis programming.
For some reason, 5-axis machining scares people. While talking with people at trade shows, or when discussing the potential of a customer’s parts being a good fit for 5-sided machining, you can just see an uneasy feeling begin to overwhelm them and fear begin to well up in their eyes. The mere thought of all of those axes moving at one time sends them wanting to run for the hills. But if we take the time to look at it logically and break it down to what is really happening, it isn’t scary at all!
If the past few years have taught us anything, it's that the addition of 5-axis technology can positively impact a company’s bottom line, even in shops that only run "3-axis work." On average, shops who take advantage of this technology have seen improvements of 20% to 30% in efficiency. Imagine what would a 20% to 30% reduction in cycle time and setup time on a part that you are already running in your shop would mean to you.
5-axis machining has become much more prevalent in today’s manufacturing marketplace, and the overall knowledge base of machinists and operators has grown by leaps and bounds over the past several years. Yet there is still a great deal of misunderstanding and mystery surrounding accuracy, both as it applies to the workpiece itself, and also how the overall positioning of the rotary axes of the machine might be affected.
For anyone new to 5-axis machining, it should quickly become apparent that fixturing can be one of the single most challenging tasks that you will face during the setup process. Although there are many different styles of professionally manufactured workholding devices available, from a variety of different manufacturers - like Kurt, Raptor Workholding, Lang, Jergens, Bock, Hirschmann, and System 3R just to name a few - creativity is the name of the game.
Hurco is well known for its powerful and easy-to-use conversational software, and for 2D and simple 3D geometries, the WinMax conversational control simply can’t be beat. But what about those jobs that share both simple 2D features and complicated 3D shapes that can only be programmed using CAD/CAM software? Hurco has an answer for that as well.
Hurco’s patented Automatic Safe Repositioning (ASR) feature is a very powerful tool for 5-axis NC or CAM programmers. One of the biggest problems when posting 5-axis NC code is configuring the post to always output safe, reliable data to reposition the tool tip without causing the machine to travel out of limits on rapid moves and display those annoying error codes that we all love to hate.
