Positional Five Axis Machining refers to 3-axis machining with part indexed using fourth and fifth axes. This technique has long been in practice due to its ability to save time by machining complex or multi-faceted features in a single set-up. Some other benefits to positional five axis machining are the effective use of short cutter due to greater reach capability; improved machining parameters (faster cutting, longer tool life); and increased accuracy simply by creating a series of orientation workplanes.
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| An example of Position Five Axis Machining. All six sides of this part are finished in a single set-up. |
Challenge
Although set-up time was reduced for the structural component shown above using positional five axis machining, the entire process was still limited with the limitations imposed by the rigidity of tool assembly, maximum spindle power and part flexibility. When the part was programmed on CAM and run on the machine, max spindle power was exceeded during roughing resulting in spindle stall; and surface finish wasn't acceptable due to vibrating flexible part.
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| Vibration problems observed during finishing. |
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| Spindle power limit exceeded during roughing. |
Approach
We used SHOPPRO vibration diagnosis system to correct spindle speed, axial and radial depths of cut for finishing and adjust CAM program; then used MACHpro Virtual Machining systems as a platform to adjust feed rate for optimum spindle power consumption during roughing and for consistent tool loading for the rest.
Results
- Excessive spindle loading during roughing eliminated
- Chatter during finishing eliminated
- Productivity improved by 25%
- Finishing tolerance met
- Tool life improved
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