Secrets of 5-Axis Machining

177 Pages·2008·37.693 MB·English

by  Karlo Arpo

KarloApro
ISBN 978-0-8311-33757
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Secrets
ot S-Axis
Machining
by KarloA pro
IndustriaPl ress,I nc.
NewY ork
Libraryo f CongressC ataloging-in-PublicatDioant a
Apro,K arlo.
Secretso f s-Axis lvlachining/ Karlo Apro.
p. cm.
Includesin dex.
rsBN 978-0-8311-3375-7
1. l4achineto ols--Numericaclo ntrol.2 . Machining.I . Title.I L Title:
Secretso f 5-AxisM achining.
TJ11B9.A6280 OB
671 .3'5--dc22
2004027254
IndustrialP ress,I nc.
989 Avenueo f the Americas
NewY ork,N Y 10018
FirstP rintingA, ugust,2 008
SponsoringE ditor: lohn Carleo
lnteriorT exta nd CoverD esign: PaulaA pro
DevelopmentaEl ditor: RobertE . Green
ProductionI\ 4anagelna net Romano
Copyright O 2009 by Industrial PressI nc., New York.
All rights reserved.T his book, or any parts thereot may not be reproduced,s tored in
a retrieval system, or transmitted in any form without the permissiono f the publisher.
All trademarks and registeredt rademarks, including Mastercam@an d Vericuto, are
property of their respectiveo wners. All rights reserved.
STATEMENTO F NON-LIABILITY
No liabilityi s assumedb y the authoro r publishewr ith respectt o use of information
contained herein, includingf or any loss of profit or other commercial,s pecial, or
incidental damages.W hile every reasonablep recaution has been taken in preparing
this book,t he authora nd pubiishera ssumen o responsibilitfyo r errorso r omissions.
Publicationo f any data in this book does not constitute a recommendationo r
endorsemenbt y the authoro r publishero f any patent,p roprietaryr ight, or product,
10 9 B 7 6 s 4 3 2
Printedb yT homsonP ressIn diaL imited
Dedication
Thisb ooki s dedicatedin, lovingm emoryt/o my motherP iroskaS. het aughtm e
the meaningo f hardw orka ndp erseverancAel.t houghs hep asseda wayb eforeth e
completioonf this book,h ers piritc ontinuetso livew ithm e.
Acknowledgements
I wouldl iket o thank Yavuzl vlurtezaoglfuo r givingm e the inspirationto write this
DOOK.
A speciatlh ankst o LauraN ortonf or her humblingi nsights.
And abovea ll, I wouldl iket o thank PaulaA pro,m y hard-workingw ife,f riend,e ditot
designera, nd managerF. orw ithouth er this bookw ouldn everh avec omet o be.
All the imagesi n this book,i ncludingth e virtualm achinesw, ere modeledu sing
f4astercam(oC NCS oftware,I nc.). The virtualm achinesw ere broughtt o life using
the machines imulationc apabilitieso f 14achSim(l" loduleworksa)n d VERICUT6
(CGTech).
Form ore informationo n theseproductso r companiesp leasec ontactl
CNC Software/Mastercam Machsim/Moduleworks CGTech/VERICUT
671 Old Post Road ModuleworksG mbH 9000 ResearchD rive
Tolland,C T 06084 Ritterstr,1 2 a Irvine, California 92618
860.875.5006 52072A achen,G ermany 949.753.1050
www.mastercam.com +49.241.4006020 www.cgtech.com
www.moduleworks.com
Form ore informationo n the author,D leasev isit www.multiaxissolutions.com
Table of Contents
Introduction ... ....., . . .1
Chapte1r : Historyofs -AxisMachine.s.. .....3
Commoln4 isconcep.t.io..n, s .... .......4
Reasontos lJseM ultiaxli\s4 achines. ,,,....,B
Chapter2!K nowYourMachine......,,,.,..13
l4ultiaxisl\4achineConfigurations .........74
Table/TableMultiaxisfl44aicllhininge s.............. 18
I\4achinReo taryZ eroP ositio(nl vlRZP) ......21
NestinPgo sitions, ............26
RotaryT ableD ynamicF ixtureO ffset. . . , , , , , , , . . . . . 27
Head/TableMultli4aixlliisnl vgl achines.............. 31
Head/HeMadu ltiaxislvlill4laincgh ines.............. 36
Findintgh eP ivoDt istance ......37
4-Axils\ 4achines .............3S
Genemll 4aintenanc&e Issuesf or 14ultiaxilsY achines. . . 40
I\4illinlg4 achinesW ith Five-o r l.4ore-Axes. .. . . . . . . . . . 43
Chapter3C: uttingStrategies..............45
i Chapter4 r Indexing MultiaxisT oolpaths . . . , .49
G Indexinlvgl ethods ........,,.51
HowC AD/CA|SVyIs temsH andleIn dexingW ork........ 56
O*=
MachineC oordinateS ystems. .
lulachinHe omeP osition . .
ActiveC oordinateS ystem . . ,
I\4achinRe otaryC enterP oint, . 60
CAD/CAMS ystemO rigin . . . 60
SynchronizinglY achinea nd CAD/CAMc oordinateS ystems .
Chapter5 : SimultaneousM ultiaxisT oolpaths. ,65
TheO ptimuWmo rkE nvelope ............70
Feedrates. .......,,72
InversTeim eF eedra,t.e .......,,,...74
PosPt rocessors. ....,........76
Chapter6 : Commons imultaneous Multiaxisc AM
ToofpathC ontrols. ,.....79
CuPt atterns. .......79
TooAl xisC ontrol. ............ 86
T o oTli pC o n t r o l . . . . . . . . . . . . . . 9 0
CollisiCoonn trol .............93
AdditionMaLl rltiaxisIssuesandControls............,98
D o v e tEa fi lf e c t . . . . . , . . . . . . . 9 8
CuttinDgi rection ..........100
IvlultiaRxoisu ghing. ........101
ChapterTMr achineSimulation....,..,,..,1O3
G-codeSimulationVersusCAMSimulation..1.0.,5.....
ConfiguringVirtMLaraclh ineFso rSimulation....,.... 105
V i r t u a l M a c h i n e B u i l d i n g . . . , , . . . . . . , . . . 1 0 6
TheS keleton .....106
Componenvtss.l t4ode.l.s. ...,......I07
MachinSei mulatiIonnt erface. s .........116
UsinMg achinSeim ulati.o,n.. ...,,....7I7
Chapter 8: Selecting The Right Machine For your
Application ...........119
Head/Head Machines (with long X or y - axis linear travel,
butl imitedro tarya xestr avel). . ......,.I21
Head/Tablel 4achines( with long X-axis travel) . . . . . . . I23
Head/Tabll4ea chine.s ,......126
RotarTy able-T iltingH eadC ombination..s. ..,....128
Table/Tablvleia chines.. ..,....I32
GantryT ypeH ead/Healdv lachines.. .,.... L34
Chapter 9! Choosing a CAD/CAM System For your
Appfic ation. ..,,.,..,,,tg7
SpeciPalu rposSeo ftwar.e... . ... ..,,.. f37
CAD/CATIo4o lbox. .,......,,139
MultiaxiscAD/CAlvlConsiderations .,..... 139
MultiaxCisA f4. .,...I4O
l4ultiaxCisA D/CATI4.a inin.g . , , ....,,..I44
Behindt he Scenes:C AD/CAMS oftwareD evelopmen.t . 145
GeneralG uidelinesf or ResearchingC AD/CAMS oftware. . 146
Chapter 10: Putting ItAII Together, . , , . . . . .149
WhyUsel4ultiaxislvlachiningTech.n..i.q..u.e..s.? 152
Whati sa Standarsd- Axisl\ 4achine? ......153
WhatistheStandardAxisConventio..n.?......... 154
What are the ThreeM ajorM ultiaxisf 4achineT ypes?. . . 154
What are the l'.lajoBr uildingB lockso f a CNCl 4achine?. 156
What are the 14osItm portantP hysicaPl ositionso f a
[4ultiaxis1 4achine? 157
WhatT oolsa re Neededt o FindM RZP?.. . 159
Descriptiono f Indexing/RotarPy ositioninWg ork. . . . . . 159
Whal i5 a PostP roccessor?. 159
DefiniLioonf an Axis 160
Defininga Simultaneou5s -axisT oolpath 160
Whata ret he ThreeC ommonS imultaneoulsY ultiaxiCs AM
ToolpathC onLrols. 161
14ultiaxiMs achineO ffsels.. . 167
Findingl YachineR otaryZ eroP osilion.. . 162
Findingt he PivotD istance 164
Indexing/RotaryPositionWorkOvervi.e.w...... . 166
Pickinga CAD/CAMS ystem for Multiaxis Work . . . . . . . 166
14achinSe imulation. 167
Conclusion 767