Multi Axis Machining

Matt Culen Jon Linard Amy Moise Karsten Tessarzik

Background
Standard 3-axis machining
allows the spindle or workpiece to move in the x-, y-, and zdirections

Multi-axis machining allows the

spindle or workpiece to rotate about these axes

Background
3-axis Milling
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

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

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

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.

Mold Making Industry

Allows complex molds
to be made quickly and efficiently Eliminates postmachining
No polishing No additional machining

Reduces labor costs

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

Economics
Traditional Machines
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

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

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

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

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

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

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

Continuous Versus Positional

Positional
Series of Discrete Operations Time benefits because of single setup Continuous Tool path along complex surfaces Ideal for profiling parts and contouring surfaces

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

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

Advantages Summary
Creation of complex contours
and parts
Simultaneous movement and feed along all 5-axes Parts dont have to be cast Reduced lead times Higher accuracy attainable Surface can be machined at any angle Reduces time and cost of producing fixtures Reduces inaccuracy in alignment due to multiple set ups

Allows machining on all 5 sides

of a part

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

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

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

Video

Resources
A Compelling Pick for Impeller Production. Modern Application News September 2006: 40.9 Methods Machine Tools Fanuc Robodrill 5-Axis Impeller Blade http://youtube.com/watch?v=fXWMDN5amzE 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 http://www.mmsonline.com/articles/090407a.html