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FeatureMILL3D 5-Axis Positioning

5-Axis Positioning
Introduction.
This module will provide the user with an introduction to 5-axis positional machining in
FeatureAM! In normal" 3-Axis machining" the machine tool has three linear axes! In 5-axis
positional machining" two additional rotational axes are added! This is o#ten re#erred to as
3$% machining! The 3$% re#ers to the three linear axes which are controlled simultaneousl&"
and the two rotar& axes which can move the part to a new position and then stop! 'nce the
part is in the new position" 3-Axis simultaneous machining is carried out! This t&pe o#
machining can onl& move the linear axes or the rotar& axes - not (oth at the same time" i!e!
positioning is discrete #rom machining!
The image a(ove shows a t&pical 5-Axis machine! In this case" the 3 linear axes )*" + , -.
are a(ove the machine" and the two rotar& axes are on the trunnion and rotar& ta(le!
The use o# 5-Axis Positioning gives a num(er o# (ene#its/
A part can (e cut in a single setup including undercuts which would normall& re0uire the part
to (e dismounted #rom the machine and set up in a di##erent orientation! This reduces the
setup time and errors that can (e introduced (& having to do multiple setups!
1& tilting the tool relative to the sur#aces (eing machined" the contact point o# the tool on the
sur#ace can (e changed giving (etter cutting conditions!
2sing shorter tools increases the rigidit& o# the tool reducing de#lection and chatter giving
improved sur#ace #inish and accurac&!
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Axis Conventions
A 3-Axis machine has 5ust the three principal linear axes" *" + and -! A 5-Axis machine will
have two more rotar& axes6 in most cases these axes will rotate around one o# the principal
axes! The naming o# these axes di##ers #rom manu#acturer to manu#acturer" (ut in most cases
the convention is/
The A axis rotates around the *!
The 1 axis rotates around the +!
The axis rotates around the -!
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Machine Configurations
A 5-Axis machine will have the *" + and - axes plus two o# the a(ove rotar& axes! The
machine shown (elow has an A axis motion where the trunnion ta(le rotates a(out * axis! It
then has a axis rotar& ta(le mounted on the trunnion which rotates around -! Please note
that the - axis here re#ers to the axis o# rotation o# the rotar& ta(le when the trunnion is in
its home position!
This is one o# the most common machine
con#igurations! It is called a Ta(le7Ta(le
con#iguration as the two rotar& motions
are (oth positioning the wor8piece rather
than moving the tool! The axis is on
top o# the A so this would (e called a
Ta(le7Ta(le machine with stac8ed on
A!
The machine shown to the le#t
moves the tool to a di##erent
rotational position (& rotating the
head o# the machine a(out the +
axis this is a 1 rotation! The part
and ta(le are rotated around the -
axis" i!e! a rotation!
This is another common
con#iguration and is 8nown as a
1 on 9ead7Ta(le machine!
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In this machine (oth o# the rotar&
motions are on the head! The upper part
o# the head can rotate around - and the
lower part around the +! This is a 1 ,
9ead79ead machine con#iguration!
The #inal machine con#iguration (elow is an Inclined Ta(le7Ta(le machine which has a axis
rotar& ta(le mounted on another ta(le which is inclined at :5 degrees! In this case the lower
rotar& ta(le is designated as the 1 axis even though it is not rotating around the + axis! This
machine con#iguration is (ecoming much more popular in recent &ears as it o##ers a large
wor8ing envelope with a small #ootprint!
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The output o# the post processor which is sent to the machine can ta8e a num(er o# di##erent
#orms6 the most common will output the rotation position explicitl& as an A and angle pair
)or A,1 or 1, depending on the machine con#iguration.! For example/
N55 G1 X-0.3398 Y1.3561 Z3.0245 A-29.206 B-116.565 S7500 M03
'ther machine controllers re0uire the rotation position as a direction vector o# the #orm I" ; ,
< where the three letters give the components o# the vector in the *" + , - directions
respectivel&! The necessar& calculations are all carried out (& the post processor! 'nce the
post has (een con#igured #or a particular machine the customer will 5ust program
FeatureAM in the normal wa&!
Turning on 5-Axis
1& de#ault in FeatureAM the tool is oriented along the setup - axis! In order to use 5-Axis
positioning" we #irst need to ena(le 5-Axis simultaneous in the =valuation options! 'nce this
is ena(led" we also need to change the stoc8 properties to allow 5-axis indexing!
Open FeatureCAM but DO NOT open an FM docuent
'n the main tool(ar &ou should onl& have two options" File and Help!
Click on Fi!e and then select "va!uation Options
Check 5 Axis Positioning
FeatureAM will give a warning that the
product component has not (een licensed!
This 5ust means that it has not &et chec8ed
the license #ile and dongle to see i# &ou have
the rights to use 5 Axis >imultaneous
positioning!
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Click App!#
I# &ou have the correct options in &our license #ile" &ou will then see the word Licensed next
to the 5 Axis Positioning option! I# &ou do not see this" then &our license #ile is not set up to
license this option on the dongle &ou are using! In this case &ou can either continue to use
FeatureAM in =valuation mode )this does not allow &ou to save." or &ou can contact &our
dealer to arrange a license!
Click O$ to close the Evaluation Options form
FeatureAM now has the 5-Axis >imultaneous option ena(led! In order to create a 5-Axis
program" we also need to set up 5-Axis indexing in the stoc8 properties!
Create a new Inch Mi!!ing docuent
On the Diensions form click Finish
Select the Indexing ta%
Check 5
th
Axis Positioning
Click App!# and then O$
The new document is now read& #or programming o# a 5-Axis part! There are a num(er o#
other things that need to (e set up in order to position the part relative to the axes o# rotation
o# the machine so that the program will produce the part correctl&! This is rather more
involved that the setup #or a 3-Axis part and di##ers depending upon the machine
con#iguration and includes some varia(les which are machine speci#ic! ?e will loo8 into the
machine speci#ic setup varia(les next!
Leave the document open for the next exercise
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&etting 'p for 5-Axis Machining
>etting up #or 5-Axis machining is more complicated than #or 3-Axis machining" and is a two
step process!
First" we have to con#igure the post processor so that it matches the actual machine (eing
used! This is a @one o##A process and involves inputting a num(er o# o##set values into the
post to allow it to carr& out the necessar& coordinate trans#orms to accuratel& position the
machine! This involves relating the pivot point o# the machine to a 8nown reference point
on the machine! For example" on a ta(le7ta(le machine this would normall& (e the center o#
the topmost ta(le! The process will involve a certain amount o# testing to #ine tune the
cali(ration o# the post! 'nce this has (een set up" it should not (e touched again unless the
machine is ph&sicall& changed" e!g! a#ter a re(uild o# a ta(le component!
It should (e noted that the post con#iguration is machine speci#ic" that is even i# a shop has
two machines o# identical ma8e and model there will (e small di##erences (etween them and
each will re0uire its own cali(rated post processor!
The second stage o# setting up applies to the particular part (eing machined and involves
relating the relative distances in *" + and - From the part setup origin To the reference
point o# the machine! This allows FeatureAM to wor8 out how the setup and the part will
move #or an& given com(ination o# rotations o# the machine axes!
'nce these two stages have (een completed FeatureAM will (e a(le to accuratel& output
5-Axis B code #or the machine! The #inal piece o# the puCCle is to set up the simulation
parameters in the part setup! This will have no e##ect on the code (ut is important i# &ou want
to carr& out machine simulations #or gouge and collision chec8ing purposes!
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Post Configuration
1e#ore an& 5-Axis machining can (e carried out" the post processor must (e #irst con#igured!
The con#iguration process is onl& done once as it is related to the ph&sical properties o# the
machine! As long as the rotar& axes are not removed #rom the machine the con#iguration
should remain valid!
The post processor contains a set o# coordinates that relate the Pivot Point o# the machine to
the Ta(le 'rigin!
The Pivot Point o# the machine is the point in space that remains still when either or (oth o#
the rotar& axes index! The pivot point is the Program !rigin i"e" D5:*3+3-3! For a vertical
spindle - ta(le7ta(le con#iguration" *3 is t&picall& at the 17-axis centerline! +3 and -3 are
alwa&s on the A-axis centerline!
The Ta#le !rigin is a 8nown location on the machine ta(le! For ta(le7ta(le machines" this is
the 17-axis centerline and t&picall& the #ace o# the 17 ta(le! This location is used (& the
post processor to calculate trans#ormations whenever there are rotations o# the A and7or 17
axis!
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From the Manufacturing menu select Post process
Click (ro)se and go to the Data folder
Select the Ma*a+ ,ariaxis.cnc post processor
Click "dit
Click on CNC Info and select 5-Axis
This opens the #orm where &ou can con#igure the post! At the top o# the #orm &ou will notice
that this is a on A Ta(le7Ta(le machine!
In the center o# the #orm &ou will see the *" + and - o##sets! These are the distances F%!&
the Pivot Point T! the Ta#le !rigin when the machine is in its home position! In this case
&ou see a * and + o##set o# -ero and a - o##set o# -%33! This means that when the ta(les are
at A' and (' the pivot point is verticall& a(ove the ta(le origin (& a distance o# %33mm!
The image (elow shows the o##sets #or another Ta(le7Ta(le machine! In this case the ta(le
origin is (ehind and (elow the pivot point and has the same * location! The o##sets that &ou
would enter in this case would (e ) '"''" * +15"'' and , +$-"4!
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It should (e stressed again E 'nce the postprocessor is con#igured" do not change these
#igures or the machine will not cut parts correctl&! The process o# getting the #igures to enter
into this #orm usuall& involves entering the #igures given (& the machine tool supplier and
then running a series o# test cuts to #urther re#ine the cali(ration #igures!
Click Cance! to c!ose the for )ithout saving an# changes
C!ose -('I.D )ithout saving changes
.oading a part into FeatureCAM
'nce we have con#igured the post processor" FeatureAM 8nows where the ta(le origin will
(e relative to the pivot point #or an& com(ination o# rotar& moves! 'nce this is esta(lished"
we can proceed to produce part programs!
The #irst thing we need to consider is the orientation o# the part relative to the .toc/ Axis!
?hen we are setting up a 3-Axis part the stoc8 axis is irrelevant" as there are no indexing
moves! ?ith a 5-axis part it is vitall& important to set the orientation o# the part correctl&
#efore &ou start programming! The stoc8 axis #ixes the angular orientation o# the part relative
to the axes o# the machine in the home position i!e! which direction * and - are pointing
relative to the part when the machine is at A3" 3! It also sets the point around which
indexing moves will rotate6 ideall& it should (e somewhere in the center o# the part!
I# &ou use the stoc8 wiCard during import" the stoc8 axis should (e set up correctl&6 i# &ou do
not use the wiCard" &ou will need to chec8 manuall&! ?e will now import a part and set it up!
Create a new inch i!!ing
docuent
Click Cancel on the stock
dimensions form
mport the file &etup.x/t
Check 'se the )i*ard!"
#ncheck .aunch AF0 after finish
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Select an Isoetric vie)
From the ,ie) enu select &ho) 1 &toc+ Axis
The imported #ile contains a part on a 5ig! The stoc8 axis is appearing at the lower le#t corner
o# the 5ig6 it loo8s li8e a setup (ut is colored (lue! As &ou can see" the part is not aligned
correctl& with the stoc8 axis! =ven i# we were to place a setup aligned with the 5ig"
FeatureAM would still regard the >toc8 Axis as (eing the A3" 3 position on the machine!
?hen we ran the program the #irst move would (e to realign the part so that the setup was no
longer aligned with the machine axes!
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Click Next
Click Pic+ 2 points to define 3 direction
Select two points up the corner of the $ig
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Click Next
Click Pic+ 2 points to define - direction
Select two points on the long edge of the $ig
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Click Next
Select a (!oc+ stoc+ and click Next
Check Copute stoc+ si*e fro the part
Click Next
%lace the setup at the center
top of the block
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Click Next
Select 5
th
Axis positioning
Click Next
FeatureAM now shows the >etup position )in the center o# the top o# the (loc8. and the
repositioned stoc8 axis )in the center o# the le#t #ace o# the (loc8.! Bote that the #irst indexing
axis in this case is the * axis! The 3
o
indicates that the part will (e @this wa& upA when the A
axis is at -ero degrees!
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Click Finish
Bow that we have the setup axis aligned correctl&" we will set up the stoc8 etc!
Positioning the part on the achine.
'nce we have the part oriented and positioned correctl& relative to the stoc8 axis the next
step is to position it relative to the Ta(le origin! FeatureAM needs to 8now where the part is
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situated on the machine ta(les so that it will 8now how its position will change when the
ta(les rotate! In the illustration (elow" the part is placed o## center on the ta(le" when the
ta(le rotates the part will move eccentricall& in a circle around the Ta(le origin as shown!
In order #or FeatureAM to (e a(le to output the correct *+-7A coordinates" it needs to
8now what the *" + and - o##sets are F%!& the Part .etup )also 8nown as the Part
Fe#erence point - this will (e the #irst setup in the part. T! the Ta#le !rigin!
In the illustrations (elow the >etup is 1ehind )-+." to the Le#t )-*. and A(ove )$*. o# the
Ta(le origin!
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Its o##set coordinates would (e )+25"$2" *+6$"'6 and ,012$"-3! These coordinates are
entered into the stoc8 properties o# the part!
&ouble click on the stoc+ to open its properties
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Select the Indexing ta% and click on Fixture .ocation
This is where the o##sets #rom the setup to the ta(le origin are entered! The #igures shown
a(ove relate to the previous illustrations! In our case we want to place the part setup in the
center o# the ta(le" so we will have -ero * and + o##sets and a positive - o##set! 1e#ore we
enter the - o##set we need to #ind out the overall height o# the part!
Click Cance!
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On the Diensions ta% click 0esi*e
Click
Copute stoc+ si*e fro the part
The overall height o# the part is 5!35G4A we need to now position the setup in the center o#
the part at the top so we can then enter the necessar& o##sets!
Click Next and then Finish
&ouble click the setup to open its properties
Click "dit
Click Next and check A!ign to stoc+ face
Click Next and select Top and Center
Click Finish
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&ouble click on the stoc+ to open its properties
Select the Indexing ta% and click on Fixture .ocation
Change the 3 offset value to be 5.45567
Click O$ then App!# followed b' O$
The part is now correctl& aligned with its setup 5!35G4A directl& a(ove the center o# the
machine ta(le! I# we were now to generate a toolpath and post process it the B code created
would (e correct #or this location on the ta(le!
I# we were to decide to locate the part elsewhere on the ta(le then we would need to go (ac8
into the stoc8 properties and change the * and + values in the #ixture location and then re-
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post the program! Provided we do not change the height o# the 5ig then the - o##set value does
not need to (e changed!
To Fe-cap" the setup #or 5-Axis machining consists o# % parts/
4. .etting up t1e post processor to fix t1e offsets from t1e mac1ine pivot point to
t1e ta#le origin2 This is machine speci#ic and onl& needs to (e done once unless the
machine is dismantled #or maintenance etc! The o##sets are initiall& ta8en #rom values
provided (& the machine tool supplier and then re#ined (& a series o# cutting tests to
Cero in on the exact values re0uired! This process is re#erred to as @ali(rating the
post processorA
%. .etting t1e position of t1e part setup relative to t1e ta#le origin2 This varies #rom
part to part and ma& (e modi#ied i# the operator decides to reposition the part on the
ta(le! An& modi#ications will re0uire the B code to (e regenerated!
&iu!ation &etup.
Finall&" we shall set up the stoc8 t&pe" include the 5ig solid as a clamp" and set up #or machine
simulation! These steps are primaril& #or visualiCation o# the machine (ehavior during the
cutting process and will not a##ect the actual B code that is output! This said it is ver& use#ul
to use a machine simulation to identi#& an& possi(le collisions o# the head with the ta(le" over
limit conditions and so on!
&ouble click on the stoc+ to open its properties
On the Diensions ta% select 'ser defined
Select the solid ps/so!id6 as the stock
Click O$ 8 App!# and then O$
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(ight click on ps/so!id2 and click 'se so!id as c!ap
Finall&" we need to position the part in the machine simulation! This is a purel& visual
location and does not a##ect the output B code! In order to set this up" we need at least one
operation so that we can run a simulation!
Create a ho!e with all of the default va!ues
Select a Machine siu!ation and click &ing!e step
Click on the 9&e!ect7 arro) on the main menu
Click on an' parts of the machine that are )in the wa'* so that 'ou can see
the position of the part on the table clearl'
The part is o## center and
#loating in space a(ove
the ta(le! ?e now need to
modi#& the location o# the
part relative to the ta(le in
the setup properties!
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&ouble click on setup6 to open its properties
Click "dit and then Next t)ice
The *"+ , - o##sets control the position o# the part relative to the ta(le!
Enter the values as shown below
Select a Machine siu!ation and click &ing!e step
Click on the 9&e!ect7 arro) on the main menu
Click on an' parts of the machine that are )in the wa'* so that 'ou can see
the position of the part on the table clearl'
The part is now
centered on the
ta(le! ?e are now
read& to prepare
and simulate 5-
Axis toolpaths
and output to the
machine!
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