AT73.

01 CAD/CAM

CAM COMPUTER AIDED MANUFACTURING BY ERIK L.J. BOHEZ AUGUST 2005

BASICS OF CNC MACHINE TOOLS

TYPES OF CNC MACHINES: -LATHES 50% -MILLING MACHINES 30% -OTHERS 20 % -EDM MACHINES WIRECUT DIESINKING -SHEET METAL MACHINES -TEXTILE MACHINES STICHING WEAVING -BENDING MACHINES -AUTOMATED STORAGE AND RETRIEVAL SYSTEMS

TAXONOMIE OF A CNC MACHINE:

-CNC CONTROL -SERVO SYSTEM -MEASURING SYSTEM -MECHANICAL STRUCTURE -PLC (PROGRAMMABLE LOGIC CONTROL) -ATC (AUTOMATIC TOOL CHANGER) -ATW (AUTOMATIC WORKPIECE CHANGER) -AXIS CONFIGURARION X Y Z A B C U V W

CNC CONTROLS
-2D 3D 4D 5D -INTERFACE RS232 RS422 RS485 ETHERNET DNC -BTR FEATURE (BEHIND TAPE READER) DRIP MODE -USERFRIENDLYNES GOOD MORNING OPERATOR -PC INTERFACE MS WINDOWS -SELF DIAGNOSIS ONLINE HELP TROUBLE SHOOTING -COLLISION DETECTION -OPEN SYSTEMS

CNC PROGRAMMING LANGUAGES

G-CODES
G01 X100.000 Y200.000 Z300.000 A360.000 B500.000 F1000 G00 X200.000 Y400.000 Z400.000 A450.000 B300.000 G90 G91 G54 M05, M01, M03

HIGH LEVEL LANGUAGE

APT (AUTOMATICALLY PROGRAMMED TOOLS) L1 = LINE/P1,P2 C1 = CIRCLE/P1,R . . GOTO/P1 GO GRAPHIC MACHINING INTERACTIVE COMPUTER GRAPHICS MASTERCAM UG VERIFICATION SOFTWARE VERICUT GRAPHIC SIMULATION OF METAL REMOVAL
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1953 vacuum tube based Numerically Controlled milling machine

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NC Lathe in 1956
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1961 NC machine based on transistors

NC Control with Integrated Circuits 1968

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1978 CNC Control with Micro-Processor

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POSITIONING LOGIC OF A CNC MACHINE:

THE SEQUENCE IN WHICH THE AXES MOVE WHEN G00 IS ACTIVE (UNDER G00 ALL AXES DO NOT MOVE SIMULTANOUS) THIS IS DIFFERENT FOR DIFFERENT TYPE OF MACHINE THE MAIN FACTOR TO SEQUENCE IS SAFETY FOR THE 5-AXIS MAHO IN AIT CIM LAB IT IS: . ??????

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Following example shows the typical CNC Part program which contains the NC words. % O503 N0001 G90 G71 G54 G94 N0002 T07 M06 S1000 M03 N0003 G00 X10.500 Y73.500 Z0.000 M08 N0004 G01 X28.000 Y73.500 F200 N0005 G02 X119.000 Y73.500 I45.5 J0.000 | N0112 M05 M09 N0113 T0000 N0114 M30 %
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Each program is identified by the program number which is right in the beginning (O503). Each line in the part program is known as Block, which is identified by the `N' word (N0001 etc). Each block contains certain other words. A typical CNC program has following words. 1) Sequence number (N word) : Used to identify the block. e.g. N0010. 2) Preparatory word ( G word) : Used to prepare the controller for instructions that are to follow e.g. G02 prepare the NC controller unit for circular interpolation along an arc in the clockwise direction. 3)Coordinates (X,Y,Z etc) : These are the geometric coordinate positions of the tool. 4) Feed rate ( F word) : Used to specify the machining feedrate of the machine. 5) Cutting speed/RPM ( S word) : Specifies the rate at which the spindle rotates. 6) Tool,selection ( T word) : Specifies which tool is to be used in the machining operation. 7) Miscellaneous functions (M word) : Specifies certain auxiliary or miscellaneous functions which are available on the machine. e.g. M03- Spindle rotate clockwise, M08- Coolant on, M06- Tool change etc Most of these Part programing langauge codes are standardised by EIA/RS244 (Electronic Industries Association), ISO/R840 (International Standard Association) and 18 DIN 66 025 international standards.

RIGHT HAND RULE

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RIGHT HAND RULE FOR ROTATIONAL AXES

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EDM DIE SINKING EDM WIRECUT RULED SURFACES COMPLEX SHAPES DEPENDS ON ELECTRODE

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PART MADE WITH A 4-AXIS DIE SINKING EDM MACHINE XYZC AXIS
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4-AXIS WIRECUT EDM AXIS CONTROL

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5-axis cnc machine

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KINEMATIC CHAIN DIAGRAM OF 5-AXIS MACHINE

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XYZCB and UV some call this a 7-axis machine

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CNC SINGLE AXIS SERVO LOOP

Tf* Vf*

X1*
. . .

Pos

Vel

Xn*

X1

V1

T1

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SLIDE OVERTRAVEL PROTECTION

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REVOLVING BALL SCREW TRANSFORM SLIDING FRICTION TO ROLLING NO BACKLASH

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UPHILL MILLING

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Conventional milling versus climb milling The direction of feed influenced machining performance. Conventional milling - up milling Feed movement opposite to tool rotation. Width of chip starts from zero and increases. Tooth meets the workpiece at the bottom of cut. Upward force tends to lift up workpiece. More power required - rubbing provoked by chip beginning at minimum width. Surface finish marred (spoiled) due to the chips being carried upward by tooth. Chips fall in front of cutter - chip disposal difficult. Faster wear on tool than climb milling. Conventional milling preferred when milling castings or forgings with very rough surfaces.
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DOWNHILL MILLING

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Climb milling - down milling Feed movement and tool rotation same direction. Width of chip starts at maximum and decreases. Tooth meets workpiece at top of cut. Easier chip disposal - chips removed behind cutter. Less wear - increases tool life up to 50%. Improved surface finish - chips less like to be carried by the tooth. Less power required - cutter with high rake angle can be used. Climb milling exerts a downward force on workpiece fixtures simple and less costly. Climb milling preferred when milling heat treated alloys, stainless steel - reduces work hardening. Climb milling way cause chipping in milling hot rolled materials due to hardened layer on the surface.

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Milling Machines Backlash

Backlash is a term that applies to machine tools. Backlash refers to the "play" or excessive amount of clearance between the machine hand wheel screw and the nut attached to the machine table or slide (Figure1).

Figure 1. Backlash
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Backlash is common on manual machine tools, especially milling machines, and is due to wear or adjustment. Backlash must be compensated for. To compensate for backlash, you must get, and keep the slide (table) and screw in contact with one another (Figure 2).

Figure 2. Screw rotation direction maintains contact between the screw and the table nut. 50

To accomplish this, when positioning the table, you must always move the table in the same direction. When positioning the table for locating a drilled hole for example, the direction you moved the table to pick up the edge of the part is the same direction the handle needs to be turned for positioning. If you go past the required setting, it is necessary to go back way from the setting at least onefourth of a turn to eliminate the backlash and then come back to the required dial setting. It is also very important to keep in mind the cut direction as it relates to backlash. On conventional milling machines, that are not equipped with backlash eliminators, the feed direction should always be against the spindle rotation (Figure 3). Figure 3. Conventional Milling
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This is known as conventional or up milling. By working the cutter rotation against the feed, the backlash is taken up. Climb milling, or down milling, must be avoided on a machine not equipped with a backlash compensation mechanism. In climb milling, the feed direction is into the cutter rotation (Figure 4).

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Therefore, climb milling, as the name implies, causes the tool to want to climb onto the part. When this happens, the workpiece gets pulled into the cutter causing the excessive cutting pressure to seriously damage the workpiece, cutter, and milling machine arbor. CNC machines are equipped with ball screws and are designed to machine with the climb milling process. Wherever possible Climb (down) milling should be done especially with larger cutters. Before operating any milling machine, find out if the machine is equipped with a backlash eliminator.

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MEASURING SYSTEM
DIRECT - INDIRECT ABSOLUTE - INCREMENTAL

DIRECT

INDIRECT ABSOLUTE ANALOG

ABSOLUTE DIGITAL DIRECT INCREMENTAL

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MACHINE TOOL COMPONENTS Mechanical structure Drives Measuring system Overtravel Protection PLC Servo Control Analog/Digital Sercos Networking
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MECHANICAL STRUCTURE
5-AXIS MACHINE HORIZONTAL/VERTICAL MILLING MACHINE 5-AXIS LATHE VIRTUAL AXIS MACHINE KINEMATIC CHAIN DIAGRAM REVOLVING BALL SCREW - BACKLASH

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DRIVES
STEPPER MOTORS DC MOTORS ASYNCHRONOUS AC MOTORS SYNCHRONOUS AC MOTORS LINEAR MOTORS

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PLC - PROGRAMMABLE LOGIC CONTROL

Cyclic Operation Cycle Time

Ladder diagram KNOW I/O OF YOUR PLC Trouble Shooting Integration

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SERVO CONTROL
ANALOG - DIGITAL SERCOS STANDARD BLOCK CYCLE TIME SERVO UPDATE RATE COMMUNICATION FIELDBUS

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Drive/Controller System Based on Analog Velocity Drive

Drive/Controller System Based on Analog Current Drive

Drive/Controller System Based on Power Block Drive

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SERCOS Ring Configuration

Profile Accuracy of an Analog System with 1000 Hz Update

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Profile Accuracy of an Analog System with 1000 Hz Update

Transmission : data Cyclic Data strings transmitted quickly within a fixed cycle and in synchronization with each other. Cyclic Transmission data includes: commanded and actual servo information. status messages. Cyclic means that, during a given cycle, the master can communicate with all drives. Non-Cyclic Data Transmission : data strings which need to be transmitted but do not require real-time processing. Non-Cyclic Transmission data includes: servo tuning parameters. limit switch +EOT, - EOT values. Non-Cyclic means that the master can communicate during a cycle with only one drive at a time

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 Data transfer takes place in telegrams. SERCOS interface recognizes three types of telegrams: Master Synchronization Telegram (MST) : is broadcast by the master at the beginning of a transfer interval. MSTs are short and are used to synchronize. Master Data Telegram (MDT) : is transmitted by the master once during a cycle. MDTs are lengthy and transfer data from the master to the drives. Drive Telegram (AT) : is transmitted by the slaves and serve to transfer data from the drives to the master.

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CNC DRIVE COMPARISON TABLE

Measur e W ires between axes and controller (includes feedback, limit switches) Extra wiring in system due to feedback connecting to both drive and controller Grounds of drive and controller interconnected Time to commission on new machine. Noise and resolution concerns SERCOS system 2 fiber-optic cables per system None No Fast Low: Very few pla ces for noise to degrade perf. All command signals are 32 bit Excelle nt High, especially for high-axis count systems Growing Drive slightly more expensive; reduced wiring and installation time, extension of I/O, drive features usually reduce overall cost. Analog 13-16 wires per 6- 8 wires per Yes MediumHigh: command resolution and commonExcellent High Analog 13-16 wires per 6- 8 wires per Yes Medium Moderate: common mode noise on command Excellent High, but powerful controller Wide Nominally priced drive, but powerful controller may be required for high Power 16-20 wires per None Usually Medium Moderate: degradati on of analog current Excellent High, but very powerful Growing Drive le ss expensive ; increased wiring and high power controller

Smoothness of profile Speed of response

Availability Cost

Wide Nominally priced drive and controller. Wiring issues can raise installed

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ROBOT FOR LOADING UNLOADING CNC

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INSTEAD OF INDIVIDUAL I/O CONNECTIONS BETWEEN PLCSEACH PLC CONNECTS TO A COMPUTER NETWORK - FIELDBUS

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FIELDBUS ADVANTAGES - CONT

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FIELDBUS ADVANTAGES - CONT

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REAL TIME CONDITION FOR CNC SERVO CONTROLLER

BLOCK CYCLE TIME } SERVO UPDATE RATE REAL TIME OPERATING SYSTEM HAS A DETERMINISTIC RESPONSE TIME
COMPUTER NETWORKING -ETHERNET STOCHASTIC RESPONSE TIME NO REAL TIME -TOKEN PASSING (RING OR BUS) REAL TIME INTELLIGENT SENSOR = SENSOR THAT CAN CONNECT TO COMPUTER NETWORK

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Reading assignment pdf file is available

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INVERSE KINEMATICS OF 5-AXIS MACHINE TOOL

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Kinematic Modeling of Machine Tool Structural Modeling of Machine Tool Thermal Modeling of Machine Tool Dynamic Modeling of Machine Tool

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WHY 5 DEGREES OF FREEDOM

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5 degrees of freedom is the minimum to position two rigid bodies in any relative position and orientation

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(Direct/Forward) Kinematics is the process of calculating the position in space of the end of a linked structure, given the positions of all the joints. It is easy, and there is only one solution. Inverse Kinematics does the reverse. Given the end point of the structure, what positions do the joints need to be in to the achieve that end point. It can be difficult, and there are usually many or infinitely many solutions.

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A=000.000 B=000.000 X=000.000 Y=000.000 Z=000.000

Machine tool reference position

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KINEMATIC CHAIN DIAGRAM OF 5-AXIS MACHINE

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O1 Fixed To part To A-Body CL-Vector x1, y1, z1, i1, j1, k1

Workpiece coordinate system O1

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O4 Fixed To Frame

O4 Machine Coordinate System

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O2 Fixed To B-Body Workpiece Offset: xO1O2 = 37.5mm yO1O2 = 64.952mm zO1O2 = 0.0 mm

O2 Coordinate System z2 coincides with A-axis

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O2 Fixed To B-Body Specific Machine Parameters: zO3O4 = - 415.000 mm

Tool Length Compensation: zTO4 = -100.000 mm O2 Coordinate System Facilitates Coordinate Transform From O2 to O3 O2 and O2 axes have same orientation
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Specific Machine Parameters: xO2O2 = 0.000 mm yO2O2 = 0.000 mm zO2O2 = -290.000 mm zO2O3 = 15.000 mm Coordinate Transform O2 to O3: x3 = - z2 y3 = y2 z3 = x2 + z O2O3
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Workpiece Moves

Rotation A Orientate CL-Vector in Horizontal Plane

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Workpiece Moves

Rotation B Orientate CL-Vector Parallel to Tool Axis

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Top View Illustrate Effect of A and B Rotation: CL-Vector Parallel to Tool Axis
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Side View Showing the Required Y and Z translation after Rotations A and B
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Side View Showing the Required X translation after Rotations A and B

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Workpiece Moves

CL-Vector Position after A and B rotation and X translation

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Top View of CL-Vector Position after A and B rotation and X translation

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Side View of CL-Vector Position after A and B rotation and X translation ( Required Y and Z Translation is clearly Visible)
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Workpiece Moves

Machine Tool Position after Rotations A and B and Translation X and Y

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Side View of CL-Vector Position after A and B rotation and X and Y translation ( Required Z Translation is clearlyVisible)
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Close Up View of Tool and Workpiece position after A, B Rotations and X,Y Translations
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A= - 45.000 B= - 35.269 X= 301.560 mm Y= 44.160 mm Z= - 330.200 mm

Machine Tool Position after Rotations A,B and Translations X,Y Of Workpiece and Translation Z of Tool
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Top View after A,B,X,Y and Z movements Tool tip and CL vector Coincide
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(* Geometry Transform for Maho600E machine - Ref Fig1 *) (* Example CL-Point *) i1 = Sqrt[3]/3; j1 = Sqrt[3]/3; k1 = Sqrt[3]/3; x1 = 100; y1 = 100; z1 = 100;

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(* Workpiece Offsets *) xo1o2 = 10; yo1o2 = 10; zo1o2 = 10; (* Machine parameters*) zo2o2p = -250.314; zo2po3 = 0.08; zo3o4 = -350; zto4 = -100;

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(* Computation of A and B angle *) A = ArcTan[j1/i1]; B = - ArcSin[k1/Sqrt[i1^2 + j1^2 + k1^2]];

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(* Coordinate Transform from o1 to o2 *) x2 = x1 + xo1o2; y2 = y1 + yo1o2; z2 = z1 + zo1o2; (* Rotation A in o2 - Positive rotation oposite ISO *) x2a = x2 Cos[A] + y2 Sin[A]; y2a = -x2 Sin[A] + y2 Cos[A]; z2a = z2;

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(* Coordinate Transform from o2 to o2p *) (* zo2o2p is a machine dependent parameter *) x2pa = x2a; y2pa = y2a; z2pa = z2a + zo2o2p; (* Coordinate Transform from o2p to o3 *) (* zo2po3 is a machine dependent parameter *) x3 = -z2pa; y3 = y2pa; z3 = x2pa + zo2po3;
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(* Rotation B in o3 *) x3b = x3 Cos[B] - z3 Sin[B]; y3b = y3; z3b = x3 Sin[B] + z3 Cos[B]; (* Coordinate transform to O4 *) x4w = -x3b; y4w = -y3b; z4w = z3b + zo3o4; (* Translation X,Y workpiece moves - and Z tool moves *) (* zo3o4 is a machine parameter *) (* zto4 is the tool length offset *) x4wX = x4w + X; y4wY = y4w + Y; z4wXY = z4w x4TZ = 0; y4TZ = 0; z4TZ = ZTo4 + Z; (* After A, B, X, Y, Z we require *) x4wX = x4TZ = 0; y4wY = y4TZ = 0; z4TZ = z4wXY X = x4w; Y = y4w; Z = z3b + zo3o4 - zTo4

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5-AXIS POSTPROCESSOR -INVERSE KINEMATICS -LINEARIZATION -FEED RATE COMPENSATION

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CAM TOOLPATH = PIECEWISE LINEAR APPROXIMATION

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REAL TOOLPATH ON 5-AXIS MACHINE IS A CURVE

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PROBLEMS WITH 5-AXIS TOOLPAT ON REAL MACHINE -CURVED REAL TOOLPATH OUT OF TOLERANCE -MACHINE SLIDE TRAVEL NOT EQUAL TO TOOLTIP TRAVEL SOLUTIONS -LINEARIZATION -FEEDRATE ADJUSTMENT

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LINEARIZATION

BECAUSE THE REAL TOOLPATH ON THE 5-AXIS MACHINE IS A CURVE THE POSTPROCESSOR WILL INSERT EXTRA CL POINTS SO AS TO APPROXIMATE THE STRAIGHT LINE WITHIN TOLERANCE
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Technological Advantages of 5-Axis machining 1.Better surface roughness

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Periodical build-up and breaking-off of the build-up cutting edge at Speed of about 50 m/min
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5-axis milling techniques Flat end mill with lead/lag tilt angle

Point Milling Cutter Contact Point (CC point) In case of 5-axis the CC point has always optimal cutting speed

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5-axis milling techniques Ruled surface swarf milling

Peripheral Milling Swarf milling cutter contact curve Very smooth surface High metal removal rate Large overcut/undercuts
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5-axis milling techniques Head milling with flat endmill super finish of convex surfaces

-Milling with the bottom of the endmill The bottom plane is tangent to the workpiece surface. -This method is only used for finishing convex surfaces - Non-optimal cutting conditions at CC point High friction - Allows to obtain excellent surface finish used to obtain optically Perfect surfaces 119

Ra in m Machined surface roughness

H I

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Shape error versus cutter orientation

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Scallop or cusp height Scallop height in case of ballnose

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Scallop height in case of flat end mill under angle

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Selection of diameter and slope of tool for concave surface

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Machining a flexible workpiece with a ballnose or flat end mill

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Dimensional deviation due to bending of the tool

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3D

5D

Machining of a rib
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STUDY OF 5-AXIS MACHINE

CLASSIFICATION OF FIVE AXES MACHINES A) ROTATION AXES ARE ON TOOL SPINDLE, B) ROTATION AXES ARE ON MACHINE TABLE C) COMBINATION OF BOTH

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FIVE AXIS M ACHINES WITH THE ROTAT'ON AXES IM PLEM ENTED ON THE TOOL AXIS SPINDLE ADVANTAGES: 0 THESE M ACHINES CAN MACHINE VERY LARGE WORKPIECES. 0 THE M ACHINE AXIS VALUES OF THE NC PROGRAM XYZ DEPENDENT ON THE TOOL LENGTH ONLY. A NEW CLAMPING POSITION OF THE WORKPIECE IS CORRECTED WITH A SIM PLE TRANSLATION. THlS HAPPENS WITH A ZERO TRANSLATION IN THE CNC CONTI:OL OF THE M ACHINE. DISADVANTAGES: 0 THE DRIVE OF THE M AIN SPINDLE IS VERY COM PLEX. ONLY IN CASE THAT THE WHOLE SPINDLE WITII THE MOTOR ITSELF IS ROTATING CAN WE OBTAIN A SIMPLE CONSTRUCTION. 0 THERE IS A LOWER STIFFNESS BECAUSE THE ROTATION AXIS OF THE SPINDLE IS LIM ITING TI-IE FORCE TRANSM ISSION. AT HIGH REVOLUTIONS PER M INUTE (HIGHER THAN 5000 RPM ) THERE IS ALSO A COUNTER ACTING MOM ENT BECAUSE OF THE GYROSCOPIC EFFECT WHICH COULD BE A DISADVANTAGE IN CASE THE TOOL SPINDLE IS TURNED VERY FAST. 0 CIRCULAR INTERPOLATION IN A RANDOM PLANE AND DRILLING CYCLES UNDER RANDOM ORIENTATION ARE OFTEN NOT IMPLEM ENTED. 0 A CHANGE IN THE TOOL LENGTH CANNOT BE ADJUSTED BY A ZERO TRANSLATION IN THE CONTROL UNIT, OFTEN A COM PLETE RECALCULATION OF THEPROGRAM IS REQUIRED. IMPORTANT APPLICATIONS OF THIS TYPE: ALL TYPES OF VERY LARGE WORKPIECES SUCH AS AIRPLANE WINGS

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MACHINES WITH TWO AXES ON THE CLAMPING TABLE; ADVANTAGES: IN CASE THAT THE SPINDLE IS HORIZOINTAL WE ARE OBTAINING IN ALL CASES OI'TIM AL CHIP REM OVAL THROUGH THE GRAVITATIONAL EFFECT OF THE CHIPS JUST DROPPING AWAY. THE TOOL AXIS DURING MACHINING IS ALWAYS PARALLEL TO THE Z AXIS OF THE MACHINE. SO THE DRILLING CYCLES CAN BE EXECUTED ALONG Z-AXIS OF M ACHINE. CIRCLES UNDER A CERTAIN ORIENTATION OF THE WORKPIECE ARE ALWAYS EXECUTED IN THE XY PLANE OF THE MACHINE. THE AHOVE M ENTIONED FUNCTIONS CAN BE EXECUTED IN THE SIM PLE 3-AXES NUM ERICAL MODE. THE COMPENSATION OF THE TOOL LENGTH HAPPENS ALL THE TIM E IN THE NC CONTROL OF THE MACHINE, AS WITH 3-AXES M ACHINES.

DISADVANTAGES: * MACHINES WITH A ROTATING TABLE ARE ONLY FOR WORKPIECES WITH LIM ITED DIM ENSIONS. * THE USEFUL WORKSPACE IS USUALLY M UCH SM ALLER THAN WITH LINEAR 3 AXES M ACHINES. THE TRANSFORMATION OF THE CARTESIAN CAD/CAM COORDINATE (XYZIJK) OF THE TOOL POSITION TO THE M ACHINE AXES POSITIONS (XYZAB OR C) IS DEPENDENT ON THE POSITION OF THE WORKPIECE ON THE M ACHINE TABLE. THIS M EANS THAT IN CASE THE POSITION OF THE WORKPIECE ON THE TABLE IS CHANGED THIS CANNOT BE M ODIFIED BY A TRANSLATION OF THE AXES SYSTEM TO THE XY SYSTEM OF THE XYZ VALUES IN THE NC PROGRAM . THEY M UST HE RECALCULATED. IN CASE THE CONTROL OF THE NC MACHINE CANNOT TRANSFORM CARTESIAN COORDINATES TO MACHINE COORDINATES, THEN A NEW CNC PROGRAM. MUST GENERATED WITH THE POSTPROCESSOR OF THE CAD/CAM SYSTEM EVERYTIM E THE POSITION OF THE WORKPIECE CHANGES. IMPORTANT APPLICATIONS FOR THIS TYPE: 0 5-SIDED CUTTING OF ELECTRODES FOR EDM , ELECTRODES AND OTHER WORKPIECE. 0 MACHINING OF PRECISION WORKPIECES. 0 TURBINES AND TIRE PROFILES WITH A CERTAIN WORKPIECE GEOM ETRY ROTATFD OVER A CERTAIN ANGLE. THE SAM E NC PROGRAM CAN HE REPEATED AFTER THE ZERO OF THE ROTATION AXIS HAS BEEN INCLINED OVER A CERTAIN ANGLE. 132

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MACHINES WITH A TURNING TABLE AI' D A ROTATING TOOL SPINDLE

NOWADAYS THERE ARE M ANY MACHINES ON THE MARKET WITH ONE ROTATION AXIS ON THE TOOL SPINDLE AND ONE ROTATION AXIS ON THE TABLE. THEY ARE HOWEVER COM BINING M OST OF THE DISADVANTAGE OF BOTH PREVIOUS TYPES OF M ACHINES AND ARE OFTEN USED FOR THE PRODUCTION OF SM ALLER WORKPIECES. THE CLAMPING SURFACE IS LIM ITED TO 400X400 MM WHICH IS HOWEVER FOR M ANY COMPLEX PARTS SUFFICIENT. A LARGER WORKING RANGE IS PRACTICALLY REALIZABLE BY EQUIPING THE M ACHINE WITH LONG SHAPE AND T-TABLE ALONG THE X-AXIS ROTATION THE CONSTRUCTION OF THIS MACHINE IS SIM PLER THAN THE PREVIOUS TYPE SO THAT ROTATING AND PENDELING AXIS CAN BE BUILT IN THE TOOL SPINDLE. OFTEN THERE IS A LARGE ANGULAR MOVEM ENT POSSIBLE OF THE TOOL. THE APPLICATION RANGE OF THIS M ACHINE IS ABOUT THE SAM E AS WITH M ACHINES WITH TWO ROTATION AXIS IMPLEM ENTED ON THE TABLE.

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CONCLUSION 5-AXES M ILLING OFFERS A LOT OF ADVANTAGES COM PARED TO THE CLASSICAL 3-AXES M ILLING:

A. REDUCTION IN NUMBER OF SET-UP CLAMPING ON M ACHINE B. A VOIDING OF UNDERCUT FOR MACHINING COMPLICA TED SHAPES C. BETTER CUTTING CONDITIONS AND BECAUSE OF THIS, LESS WEAR OF THE TOOL D. BETTER SURFACE QUALITY THE USE OF FLAT END-M ILLS TO MAKE CURVED SURFACES WILL REDUCE PROCESSING TIM E VERY MUCH. SOM E WORKPIECES M AY BE MANUFACTURED MORE PRECISELY BY THE RIGHT CHOICE OF THE ANGLE OF CUTTER RELATIVE TO WORKPIECE AND ALSO BY SELECTING AN APPROPRIATE PROCESSING M ETHOD.

THERE ARE HOWEVER SOM E DISADV ANTAGES:

A. HIGH PRICE OF 5-AXES MACHINE B. MORE POWERFUL CNC CONTROL IS NECESSARY C. ADDITIONAL ROTATION AXIS CAUSE ADDITIONAL POSITION ERROR D. THE HIGHER CUTTING SPEEDS ON THE M ACHINE AXIS FOR THE SAM E FEED E. PROGRAMMING IS ONLY POSSIBLE WJTH SPECIAL PROGRAMMING TOOLS SYSTEM .

PROGRAMMING OF 5-AXES IS STILL A VERY COM PLEX BUSINESS. THE SIM ULATlON OF OPERATIONS AND DETECTION OF COLLISION IS VERY DIFFICULT. THE PURCHASE OF A 5-AXES MACHINE MUST BE PRECEDED BY A PROFOUND STUDY OF THE RANGE OF PRODUCTS WHICH HAVE TO BE MACHINED. BECAUSE OF THE SPECIAL CONSTRUCTION A SPECIFIC 5-AXES M ACHINE WILL BE M OST APPROPRIATE FOR A SPECIAL SET OF WORKPIECES. SO M ACHINES WITH A TURNING TABLE ARE FOR EXAMPLE VERY GOOD TO PRODUCE ROTATIONAL WORKPIECES SUCH AS COM PRESSORS. HOWEVER FOR THE PRODUCTION OF LARGE STRUCTURAL ELEM ENTS IN AERODYNAM ICAL INDUSTRY A MACHINE WITH A SUITABLE TOOL SPINDLE IS TO BE PREF'ERRED.

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OVERVIEW OF DIFFERENT FIVE AXIS MILLING APPLICATIONS - POSITIONING:

*DRILLING, TAPPING, BORING AND FACING UNDER ANY ANGLE IN ONE SET UP *SMALL NUMBER OF BLOCKS IN CNC PROGRAM (+/- 100 BLOCKS) *MANUAL PROGRAMMING POSSIBLE *5 AXIS MACHINE WITH TWO AXIS CNC CONTROL

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OVERVIEW OF DIFFERENT FIVE AXIS MILLING APPLICATIONS - CONTOURING:

* * * * * COMPLEX SURFACES, ELECTRODES FOR EDM DIE-SINKING DOUBLE CURVED SURFACES VERY LARGE CNC PROGRAMS (+/- 100,000 BLOCKS) IMPOSSIBLE WITHOUT GOOD CAM SYSTEMS 5 AXIS MACHINE WITH 5 AXISCONTOURING CNC CONTROL IS REQUIRED

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SELECTION OF MACHINE AND CNC CONTROL - MACHINE CONFIGURATION:

AXIS CONFIGURATION RANGE OF ROTATIONAL AXIS MOTION ACCURACY MEASURING SYSTEM SPINDLE SPEEDS POWER FEEDRANGES TOOLCHANGER - - CNC CONTROL MUMBER OF SIMULTANEOUSLY CONTROLLED AXES MEMORY BTR FEATURE (BEHIND TAPE READER) DATA TRANSFER SPEED PC KEYBOARD DIRECT NUMERICAL CONTROL (DNC) USERFRIENDLYNESS (GOOD MORNING !!!) PROCESSOR SPEED SELF DIAGNOSIS
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- TOOLING FOR THE MULTI-AXIS MACHINES SMALLER AMOUNT OF TOOLS STANDARD TOOLS LESS FTXTURES -CAD/CAM SYSTEM FOR PROGRAMMING MULTI-AXIS MACHINES MUST BE ABLE TO GENERATE CORRECT 5 AXIS TOOL PATHS POSTPROCESSOR. PROGRAM VERTFICATION AND COLLISION DETECTION

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DEFINITION OF MACHINE TOOL any stationary power-driven machine that is used to shape or form parts made of metal or other materials. The shaping is accomplished in four general ways: (1) by cutting excess material in the form of chips from the part; (2) by shearing the material; (3) by squeezing metallic parts to the desired shape; and (4) by applying electricity, ultrasound, or corrosive chemicals to the material.

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Computer-aided machining Computer numerical control (CNC) Adaptive control Machining centers Computer-aided design and computer-aided manufacturing (CAD/CAM) Robots Flexible manufacturing system (FMS) Computer-integrated manufacturing

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Nonconventional methods of machining Electrical methods of machining Electron-beam machining (EBM) Electrical-discharge machining (EDM) Electrochemical machining (ECM) Ion beam machining (IBM) Laser machining (LM) Plasma arc machining (PAM) Other methods of machining Ultrasonic machining (USM) Chemical machining (CHM) Photochemical machining (PCM) Water-jet machining

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LATHE

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LATHE CUTTING TOOL

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CUTTING TOOL TYPES

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BORING ON A LATHE

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MILLING MACHINE

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MILLING TOOLS

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TOOL HOLDING

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SPRING COLLETS

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FACE MILLING

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DRILLING MACHINE

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THREAD TAPS AND DIE

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BAND SAW

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METAL CUTTING THEORY

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Build up edge formation for steel cutting at about 50m/min

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BUILD UP EDGE

The build up edge is periodically deposited on the part

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GRINDER

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SHEAR

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NOTCHER

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PRESS BRAKE

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SHAPER

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SLOTTER

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PLANO MILLER

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Kinematic Modeling of Machine Tools Structural Modeling of Machine Tools Thermal Modeling of Machine Tools Modeling Machine Tool Dynamics

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The figure illustrates a Hexapod-type machine tool of the Stewart platform, which is one of the most typical parallel mechanism structures. It has six telescoping struts, each of which is connected to the base by a 2-DOF (degrees of freedom) joint. The other end of each strut is connected by a 3-DOF joint to the platform, where a machine spindle is installed. The 6-DOF control of the spindle position is possible.

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Motion Accuracy: On a parallel-link machine, the position of the spindle head is indirectly estimated from the rotational position of servo motors. Therefore, for its high accuracy motion control, it is crucial to accurately identify all the mechanical parameters such as the length of struts or the position of joints. Furthermore, the deformation due to the gravity is a critical issue for parallel-link machines. In particular, when it is driven near the edge of its workspace, the motion accuracy gets considerably worse than that of conventional serial-mechanism machines.
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Stiffness: Since the spindle unit is supported only by struts, the stiffness against the disturbance, such as a cutting force, is not as high as that of serial-mechanism machines. Currently, in many cases, parallel-mechanism machine tools are used only for the machining of soft materials, such as an aluminum alloy.

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A Double Ball Bar (DBB) Test on a Parallel Mechanism Machine Tool for Calibration

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RULED SURFACE MILLING -High metal removal rate -Smooth surface -However large undercut in no special algorithms are use

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Large Overcut

Special ruled surface milling algorithm

Tool end in plane of tangent and Normal to border curve a Reduced overcut

Move tool along Nm To minimize overcut

Tool end in plane of middle between a and b

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