Secrets of 5-Axis Machining + Bonus CD - Karlo Arpo [2008, PDF, ENG]

Chapter 1: History of 5-Axis Machines........3
Common Misconceptions........................4
Reasons to Use Multiaxis Machines.................8
Chapter 2: Know Your Machine.............13
Multiaxis Machine Configurations.................14
Table/Table Multiaxis Milling Machines..............18
Machine Rotary Zero Position (MRZP)..............21
Nesting Positions.............................26
Rotary Table Dynamic Fixture Offset...............27
Head/Table Multiaxis Milling Machines..............31
Head/Head Multiaxis Milling Machines..............36
Finding the Pivot Distance......................37
4-Axis Machines.............................39
General Maintenance & Issues for Multiaxis Machines ... 40
Milling Machines With Five- or More-Axes............43
Chapter 3: Cutting Strategies..............45
Chapter 4: Indexing Multiaxis Toolpaths.....49
Indexing Methods ...........................51
How CAD/CAM Systems Handle Indexing Work........56
Machine Coordinate Systems....................57
Machine Home Position ......................57
Active Coordinate System ....................57
Machine Rotary Center Point...................60
CAD/CAM System Origin.......................60
Synchronizing Machine and CAD/CAM Coordinate Systems . 61
Chapter 5: Simultaneous Multiaxis Toolpaths. .65
The Optimum Work Envelope....................70
Feedrates..................................72
Inverse Time Feedrate.......................74
Post Processors..............................76
Chapter 6: Common Simultaneous Multiaxis CAM Toolpath Controls.......................79
Cut Patterns................................79
Tool Axis Control.............................86
Tool Tip Control..............................90
Collision Control.............................93
Additional Multiaxis Issues and Controls.............98
Dovetail Effect.............................98
Cutting Direction..........................100
Multiaxis Roughing.........................101
Chapter 7: Machine Simulation............103
G-code Simulation Versus CAM Simulation..........105
Configuring Virtual Machines For Simulation.........105
Virtual Machine Building.......................106
The Skeleton.............................106
Components vs. Models.....................107
Machine Simulation Interfaces..................116
Using Machine Simulation.....................117
Chapter 8: Selecting The Right Machine For Your Application..............................119
Head/Head Machines (with long X or Y - axis linear travel, but limited rotary axes travel)..................121
Head/Table Machines (with long X-axis travel).......123
Head/Table Machines ........................126
Rotary Table - Tilting Head Combinations..........128
Table/Table Machines.........................132
Gantry Type Head/Head Machines................134
Chapter 9: Choosing a CAD/CAM System For Your Application............................137
Special Purpose Software......................137
CAD/CAM Toolbox...........................139
Multiaxis CAD/CAM Considerations...............139
Multiaxis CAM..............................140
Multiaxis CAD/CAM Training....................144
Behind the Scenes: CAD/CAM Software Development . . 145
General Guidelines for Researching CAD/CAM Software. . 146
Chapter 10: Putting It All Together.........149
Why Use Multiaxis Machining Techniques?..........152
What is a Standard 5-Axis Machine?..............153
What is the Standard Axis Convention?............154
What are the Three Major Multiaxis Machine Types? . . . 154
What are the Major Building Blocks of a CNC Machine? . 156
What are the Most Important Physical Positions of a Multiaxis Machine?..........................157
What Tools are Needed to Find MRZP?.............159
Description of Indexing/Rotary Positioning Work......159
What is a Post Proccessor?.....................159
Definition of an Axis.........................160
Defining a Simultaneous 5-axis Toolpath...........160
What are the Three Common Simultaneous Multiaxis CAM Toolpath Controls............................161
Multiaxis Machine Offsets......................161
Finding Machine Rotary Zero Position..............162
Finding the Pivot Distance.....................164
Indexing/Rotary Position Work Overview...........166
Picking a CAD/CAM System for Multiaxis Work.......166
Machine Simulation..........................167
Conclusion................................167

Machine Simulation
[*]Vertical, 5-axis, Head/Table machine cutting a turbine blade using dynamic Tool Axis
Control
[*]Haas EC400 horizontal, 4-axis machine demonstrating simple positioning work
[*]Huron vertical, 5-axis, nutating, Table/Table machine cutting a dish using a single
point for Tool Axis Control
[*]Haas VF2, vertical, 5-axis Table/Table machine cutting a blade of an impeller
[*]Mori Seiki NMV5000 vertical, 5-axis, Table/Table machine cutting a model of a human
head, using a spiral Cut Pattern applied to an underlying clean core
[*]Chiron, vertical, 5-axis, Table/Table machine demonstrating indexing toolpaths.
[*]Mitsubishi, vertical, 5-axis, Head/Head, laser cutting machine cutting a motorcycle
fender, using 3D curves for Cut Pattern.
[*]Haas VF2, vertical, 5-axis, Table/Table machine cutting a turbine rotor using lines
for Tool Axis Control.
[*]Okuma MU400A, vertical, 5-axis, Table/Table machine cutting a mold core, with the A-
axis locked to 45 degrees.
[*]Chiron Magnum, vertical, 5-axis, Table/Table machine cutting one side of an impeller
blade using a curve for Tool Axis Control.
[*]Okuma Millac 853PF, vertical, 5-axis, Head/Head machine cutting an aerospace
component, controlling both the Cut Pattern and Tool Axis with a Swarf toolpath.
[*]Mori Seiki NMV5000 vertical, 5-axis, Table/Table machine cutting a blade on a blisk.
[*]Mori Seiki NMV5000 vertical, 5-axis, Table/Table machine cutting the floor on a
blisk.
[*]Chiron, vertical, 5-axis, Head/Table machine cutting a floor on a component, morphing between two curves while keeping the tool axis locked around the A-axis.
[*]Chiron, vertical, 5-axis, Table/Table machine demonstrating 5-axis simultaneous motion
[*]Chiron, vertical, 5-axis, Table/Table machine cutting the floor on a split impeller
[*]DMU60, vertical, 5-axis Head/Table machine, demonstrating Tool Axis Control normal to a surfac.
[*]DMU60, vertical, 5-axis Head/Table machine cutting a test part demonstrating indexing and simultaneous machining.
[*]Haas VF2, vertical, 5-axis Table/Table machine cutting a test part demonstrating indexing and simultaneous machining.
[*]Mitsubishi Laser, vertical, 5-axis Head/Head machine cutting a test part demonstrating indexing and simultaneous machining.
[*]Haas VF2, vertical, 5-axis Table/Table machine cutting a test part demonstrating
indexing and simultaneous machining with material removal.
[*]Okuma MA400, horizontal, 5-axis Table/Table machine cutting a test part demonstrating indexing and simultaneous machining.
[*]Okuma 800vh, vertical/horizontal, 5-axis Head/Table machine cutting a test part demonstrating indexing and simultaneous machining.
[*]Bostomatic, vertical, 5-axis Head/Table machine cutting a headport driving the center of the probe/tool
[*]Huron vertical, 5-axis nutating Table/Table machine performing a trimming operation using 2 point tool axis control
Machining Videos
[*]Induction pump in different stages of 5-axis machining.
[*]Plunge roughing performed on a turbine blade.
[*]A semi-finishing toolpath performed on a turbine blade.
[*]A floor finishing toolpath performed on a turbine blade.
Machine Simulation Videos
[*]Kuka 6-axis robot, showing off its flexibilities.
[*]Mori Seiki NMV5000 vertical, 5-axis, Table/Table machine demonstrating test cuts when
[*]MRZP and Program Zero are coinciding. TCP is not active.
[*]Mori Seiki NMV5000 vertical, 5-axis, Table/Table machine demonstrating test cuts when
the part is moved in relation to MRZP. TCP is active.
[*]Head/Table machine is demonstrating both RTCP (Rotary Tool Control Point) and RPCP
(Rotary Part Control Point).
[*]2-axis, vertical Head/Table machine cutting a design into a bowling ball.
[*]Forest Line vertical 5-axis Head/Head machine cutting a test part.
[*]Engine head cut on a vertical, 5-axis, custom, dual rotary mechanism
Printable PDFs
[*]Quiz found in Chapter 10
[*]Quick Reference graphic showing Machine Offsets
[*]Quick Reference for finding Machine Rotary Zero Point
[*]Quick Reference for finding Pivot Distance
[*]Catalog of ten different machines with all axes illustrated