1.1 Overview Don’t have to stop to open door Table rotates in B C spins Computer controlled machine Uses both indexable/rotating cutting tools and indexable/rotating workpieces Setup reduction Through spindle coolant Increased flexibility Improved efficiency Enhanced accuracy Reduced tooling costs Versatility Reduced scrap/material waste Checkpoint:
1 setup, if it takes more than one the multi-axis machine can do it for us
The challenges I faced were having to adjust my part when designing to make it easier for the machine
Simplifies set up because of the newer technology and gives better accuracy
If you break a tool, you could use another tool in the carousel to repolace it instead of buying a new one
1.2 Multi-axis types 4 and 5 axis multi-axis are the most popular in machining 4th asis have 3linear axis X, Y and Z they also have one rotational axis A You could do a 6 sided die with only 2 setups on a multi-axis Utilizes integrated pallet systems to decrease set up times 5 axis VMC’s are quickly growing in machine shops now other than 10 years ago Reasons for this are Lack of machines 10 years ago lack/inhibility of CAM tools to utilize all axis Lack of CNC programmers that know how to program multi-axis machines These machines have 3 linear axis X, Y and Z, they have 2 rotational axis A and B Lathes that can mill: They have live tooling fixed parallel to the turning spindle axis They have radial live tools fixed perpemndicular to the turning spindle axis Mills that can turn: Has high RPM rotational axis A and B Is able to rotate a axis at high enough RPM’s, mills can efficiently utilize live tooling Indexable turning tools/spindle By indexing a single point live tool in a milling spindle, you can move the tool against a rotating workpiece to achieve turning Robots: Flexable automation tools used for a wide variety of applications Used for subtractive manufacturing are 6 axis industrial robot arms
1.3 Applications Positional multiaxis machining Most common way multi-axis CNC machines are used today Involves positionin one or more axis to a fixed location while the remaining axis move around the others stay fixed Programming boils down to defining a new plane, then resuming with the regular tool paths perpendicular to the new plane Can take as many 3 axis CNC program/part and reducet it down to a 1-2 op part Useful for machining on non-orthogonal planes Simultaneous multi-axis machining Invloves synchronized, simultaneous motion of all axes on a multi-axis CNC machine Simultaneous allows for machining of highly complex geometries not possiby of prohibitevely complex with other meathods
2.1 4-axis overview Durning the 4-axis machining process, two cutting tools work simultaneously to increase metal removal rates This process is ideal for cylindrical or shaft parts Upper and lower turrets greatly reduce cycle time, up to 40% Simultanious cutting with shorter setups and more parts per shift provides increased machine utilization, fewer required machines, higher operator productivity, less cost per part Increased tool capacity and fewer changeovers Types: Dedicated (Horizontal) 3+1 4-axis machining basics Positional Simultaneous
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2.2 4-axis workholding and fixturing Rotary Indexers are devices that let the workpiece be rotated around a specific axis. they typically have a chuck or collet to hold the workpiece securely. Indexers can be programmed to rotate the workpiece at specific angles, allowing machining operations to be performed on multiple sides without the need for manual repositioning. Advantages: Simple to set up and use, provides precise angular positioning, suitable for high-volume production of parts with similar features. Limitations: Limited to rotational movement only, may not be suitable for complex geometries requiring tilted angles. Trunnion Tables are mounted on the machine table and can tilt about a rotary axis. This provides flexibility in positioning the workpiece, enabling machining operation on multiple faces with complex geometries. Advantages: Enables multi-axis machining in a single setup, versatile for a variety of part geometries, reduces the need for multiple setups. Limitations: May require additional setup time for complex parts, limited in size for very large workpieces.
Tombstone Fixtures are vertical fixtures with multiple sides, each containing clamping surfaces. These fixtures are mounted on the machine table and can hold multiple workpieces simultaneously. The sides of the tombstone can be machined in a single setup. Advantages: High production throughput, Simultaneous machining on multiple workpieces, reduces the need for frequent tool changes. Limitations: limited to parts that fit within the tombstone envelope, challenging for parts with irregular shapes. Pneumatic or hydraulic vises with rotary axes are traditional vises that are enhanced with rotary axes, allowing the workpiece to be rated during machining. Pneumatic or hydraulic actuators enable quick and precise adjustments. Advantages: Combines traditional vise clamping with rotary movement, simplifies setup for parts requiring rotation, versatile for various part geometries. Limitations: Limited to the size and weight capacity of the vise, may not be suitable for large or heavy workpieces. Custom Fixtures are design to the specific requirements of a workpiece. These car include a combination of rotary and tilting elements to achieve the desired machining orientation. Advantages: Adaptable to a wide range of part shapes, offers flexibility in holding a positioning, can optimize setup for specific machining operations. Limitations: Design and fabrication may be time-consuming, may have a higher initial cost for custom solutions.
2.3 4-axis hardware setup Setup: Put air hose through hole in top of machine, pu cables through the same hole, place rotary axis on the machine table and ensure the key fits into the slots, finger tighten bolts, indicate the face of the rotary axis until the dial reads zero all the way around, then finish tightening bolts, E-stop and power off pendant, switch off power to machine, connect air hose to port inside service cabinet, connect electrical cables to their corresponding ports labled A while power is off, switch power on and start machine, do not home out or release E-stop, press setng graph, type 30 and press down arrow key to bring up the number 30, 4th-axis enable, use arrow keys to scroll through different attachments, stop on the one that matches the rotary axis, press write/enter, release E-stop, press reset, close doors, power up restart, the machine will home and the 4th axis is now ready to use Pros: Gives access to more faces, hold multiple parts Cons: centerline too close to table, bodies of units take up table space
2.4 software setup Enable: Setting, tab over to rotaries editor, enter rotary model, press F1, find correct file, press enter, verify rotary is mounted, if correct press enter again, press E-stop, F3, cycle power to initialize rotary selection, Disable: Settings, rotary tab, select rotary unit, E-stop, currenot axis highlighted, press enter, axis will disappear, do the same for all other axis Clear: Settings, rotary tab, scroll to new rotary selection, press origin, enter to confirm, after uploaded cycle power Tool change safety: Alias our own M06 tool change with this customization te rotary will straighten itself out and move to a safe position Parameter M Macro Call o9000, enter 6, changes M6 so program will run subprogram o9000, move axis manually to safe position, add M16 (tool change), add M99, finish program Zero rotary: Serttings, 108, down arrow, right arrow to turn on, enter Code for quick unwind, rapid to 0 degrees incrementally away from a-axis home position, telling it to go straight home, G90 at the end