Table Of Content

KarloApro ISBN 978-0-8311-33757 llillftftrinilllnfllii llllllllllll 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