5-Axis Machining Some Best Practices Longxiang Yang FANUC America - - PowerPoint PPT Presentation
5-Axis Machining Some Best Practices Longxiang Yang FANUC America IMTS 2018 Conference September 11, 2018 Full Utilization of 5-axis Machines 5-axis machines were developed and used in production more than 50 years Because of
– 5-axis machines with table-table configuration from OKK, Matsuura and GROB – Customer used some 5-axis functions like TCP and WSEC but has stopped using them since the NC programmer left
Rotary axes do not move in a cutting block. Only X, Y and Z-axis are commanded in a cutting block.
Plane Command
cutting results
Rotary axes move in a cutting block. All five axes X, Y, Z, A and C are commanded in a cutting block
airplanes
about 40%-50% of 5-axis machines are used in 3+2 machining
3-axis machine 5-axis machine
3-axis machine 5-axis machine
3-axis machine 5-axis machine
3-axis machine 5-axis machine
3-axis machine 5-axis machine
functions
simultaneous 5-axis machining
machining
linear and rotary axes
Actual Cutting CAD/CAM Setup
X Y Z
Part Inspection Simulation CNC/Servo Servo Guide 3D Viewer
Features need to be considered:
TCP with physical rotary axes G43.4 H1 Xx Yy Zz Aa Bb TCP with tool vector I/J/K G43.5 H1 Xx Yy Zz Ii Jj Kk
Control point is pivot point Control point is TCP
TCP generates more accurate surface
Posture Control OFF Posture Control ON
Without Tool posture control: Two rotation axes are linearly interpolated and tool posture may not be on a plane With Tool posture control: Two rotation axes are controlled so that tool posture is on a plane
Cutting point command G43.8 H1 Xx Yy Zz Aa Bb L2 Ii Jj Kk Cutting point command Same program can be used with different types of tools
Features need to be considered:
G41.2 (G42.2) D1 ;
G41.3 D1 ;
Tool axis Offset path Programmed path Offset vector Offset plane Tool axis Offset plane Offset vector Offset path Programmed path
Tool side offset Leading edge offset TCP and 3DCC are the most important compensation functions for 5-axis machines
Two program coordinate systems:
Background
coordinate needs to be selected
table type Advantages of Table Coordinate
Recommendation:
How does it work
moves along the edges of rectangle
coordinate
Move to Point 1: In table coordinate: X0 Y0 C0 ABS X=0, Y=0, MACH X=10, Y=50 In workpiece coordinate: X0 Y0 C0 ABS X=0, Y=0, MACH X=10, Y=50 Move to Point 2: In table coordinate: X10 Y0 C90 ABS X=10, Y=0, MACH X=0, Y=30 In workpiece coordinate: X-10 Y-20 C90 ABS X=-10, Y=-20, MACH X=0, Y=30
compensate any misalignment in TCP and 3DCC
G54; G54.4 P1; G43.4 H1;
C
G54 at table rotation center G54.4 P1 X’ Z’ Y’ Z Y X
10 10
X’ Y’ 1 2 3 4 X Y G54
C=0 C=90
X’ Y’ 1 2 3 4 table coordinate G54.4 P1 G54 X Y
C=90
1 2 3 4 Work coordinate G54.4 P1 X Y X’ Y’ G54
Table coordinate Workpiece coordinate
system so that – 2.5D or 3D milling can be done in a slanted surface – Canned cycles or custom cycles can be used – Same feature on different planes can be machined using the same program
comprehensive.
3DCC with Workpiece Setting Error Compensation
Flexible Command Formats
Program Format (Euler’s angle) G68.2 Xx Yy Zz Ii Jj Kk G53.1 (automatically position rotary axes to make tool perpendicular to the slanted plane)
Easy Programming on CNC
x z y x’ y’ α β X’ z y’’ z’’ y’ β γ Zc Yc Xc x’ y’’ γ
Euler’s Angle Transformation
High Speed Smooth TCP:
and tip such as airplane parts
Smooth Tolerance+ Control:
(different algorithm)
High Speed Smooth TCP cutting example:
HS Smooth TCP OFF
Smooth surface Faceted surface
HS Smooth TCP ON
Spindle Probe Tooling ball
Easy input screens are developed
execution and manual operation
interference alarm and movement is stopped
tools and workpiece
machine for more accurate checking
δB and δC for 3D grid for linear axes and 2D grid for rotary axes
improves the machining accuracy
posture by SERVO GUIDE
– Part program command – CNC command – Feedback
in 3D viewer and minimized by servo tuning
in 3D view
SERVO GUIDE
Y Z X B C
3D tool path Impeller
Before tuning After tuning Command path Feedback path
Magnified display of 3D error between command and feedback Color-coded display of 3D path error
Large deviation Small deviation
color scale
Before tuning After tuning
machining functions
CNC PC software Parameters Configuration Proper G code
– TCP: G43.4 H1 – 3DCC: G41.2 D1
most important for 5-axis machining
together with TCP and 3DCC
tooling” has to be used for certified programs, or programs have to be generated for different tools
– HSTCP: G43.4 H1 P3 – ST+C: G5.1 Q3
machining) provides better results
codes, but a lot of customers are not aware of this.
functions and got very good results (Boeing, PWM etc.)
G68.2
coordinate, very flexible
for 3+2 machining in industry
TCP can be used in TWP
(Boeing, Exotic Metal, Primus etc.)
G54.4 P1
setting error in translations and rotations
coordinate and machine-based program coordinate
(Flow, Boeing, PWM, GKN/Six Digma, Line etc.)
does not reflect the complexity of in production parts.
developed their own acceptance test
– reveal more defects on a machine – setup issues for servo and CNC
acceptance test for all machines.
NAS 979 part Boeing RR part
as cutter comp interference check etc.
Boeing R2D2 part
advantages
machines
advantage of the development due to lack of understanding
machining
– fine surface technology – Easy of use/application – AI application (machine/tool/machining condition/programming/CNC/Servo)
NC programming community and end users to promote 5-axis machining technology
Gardner 2016World Machine Tool Survey