FIVE-AXIS MACHINING
Five-Axis Machining Challenges Shops’ Core Competencies “By moving into fi ve-axis machining, shops limit the number of horizontals that they need and are able to take on more complex components that have higher value and, most important, higher machine rates,” said Scott Walker, presi- dent, Mitsui Seiki USA Inc. (Franklin Lakes, NJ). Five-axis machines process parts effi ciently, take up less shop-fl oor space—with one fi ve-axis machine typically replacing three horizontals—and can double shop machine rates. “With most fi ve-axis machined parts fi tting into a 500-mm cube or less, the majority of fi ve-axis machines purchased by job shops are vertical machines. Our most popular fi ve-axis machine is the Mitsui Seiki HU 63 fi ve-axis horizontal with a 630-mm table and 950-mm swing, especially for machining precision aerospace workpieces,” said Walker.
“Typically, fi ve-axis applications require a minimum of 180 tools and that’s for the simple parts.”
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When a job shop migrates to fi ve-axis machining, its core competency and engineering philosophy needs to be up- graded in every aspect of their operations including person- nel training, processes, software and CNC controls. “One of the fi rst questions I ask shops is how toolpath is going to be generated. Five-axis machining requires sophisticated CAD/ CAM software like that used typically by aerospace and tool and die shops,” said Walker. “Other requirements include col- lision software, probing macros written for fi ve-axis machin- ing and tool breakage detection systems. We’ve developed fi ve-axis probing routines on a Fanuc-based CNC specifi c to trunnion machine design as have Heidenhain and Siemens.” Shops will have to add signifi cantly more tools for fi ve-axis applications. “Typically, fi ve-axis applications require a mini- mum of 180 tools and that’s for the simple parts. Not only do you want redundancy in there, but there are so many more features to be machined on a fi ve-axis part versus a three-axis part,” said Walker. “Machine diagnostics to avoid unnecessary downtime and anything that adds intelligence to the machine to minimize possible operator intervention are all highly desirable.”
Boring. Reaming. Threading. Milling.
Additive/Subtractive Combined in a Five-Axis Hybrid Machine With a great deal of fanfare, additive/subtractive technol- ogy has been added to a fi ve-axis machine platform on the Lasertec 65 3D hybrid from DMG MORI (Hoffman Estates,
52
AdvancedManufacturing.org | July 2015
KOMET engineers and manufactures tools in the U.S.
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