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Hurco Applications Engineer Michael Cope's presentation for the Purdue University student chapter of the Society of Manufacturing explains why 5-Axis Machining is a "must have" in 21st century manufacturing.
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The Power of Five
What is it?
Trunion Machines
Machine Configurations
Swivel Mach
ines
Parts…
Why 5-Axis?…because time is money
Current setups take too long
Lot sizes are shrinking
Parts are getting more complicated
Looking for new opportunities
Why 5-Axis?
Traditional 3-Axis Long tools are necessary
for deep cuts Creates problems for fine
finishing operations – especially small diameter tooling
Mold Work
5-Axis Deep cuts are no problem Shorter tools can be used Faster feedrates possible Heavier cuts Shorter total cycle time
What is the difference?…five sided ? ...3+2 ? ...simultaneous ?
5-Sided (3+2) Simple to program Cuts faster Fewer tool
interference concerns
5-Axis vs. 5-Sided
5-Axis (Simultaneous) Better surface finishes Longer tool life Allows the tool to reach
difficult places smoothly impressive but slow –
avoid if possible
3-Axis vs. 5-Sided…old vs. new
3-Axis Machining Multiple setups for
each side of the same part
Increased setup time
Decreased accuracy
5-Sided Machining Reduces setup
times Increases part
accuracy Increases shop
capability
Let’s Compare…
5-Sided Setup Bolted directly to fixture No Stop necessary Two Operations
Traditional Setup Standard 6” Vise Typical Vise Stop Multiple
Operations
Operation Setup Time Load Time Cycle Time Description1 30 min 20 sec 3 min 58 sec Drill top holes and C'bore2 30 min 20 sec 0 min 42 sec Facemill back side3 30 min 20 sec 1 min 07 sec Facemill front & mill pockt4 30 min 20 sec 2 min 29 sec Mill, drill & notch right side5 30 min 20 sec 2 min 23 sec Mill & drill left side6 1 hr 30 min 20 sec 5 min 05 sec Mill front angle, drill & C'bore - built fixture to cut angle7 1 hr 30 min 20 sec 4 min 03 sec Mill back angle - built fixture to cut angle
Total 5 hr 30 min 2 min 20 sec 19 min 47 sec
Operation Setup Time Load Time Cycle Time Description1 30 min 20 sec 1 min 20 sec Drill, C'bore top side2 1hr 20 sec 11 min 44 sec Complete the rest of the part
Total 1 hr 30 min 40 sec 13 min 04 sec
Time Savings 4 hrs 1 min 40 sec 6 min 43 sec
Standard 3 Axis
Hurco VM10U 5-axis
Easy transition to 5-sided workVTXU
VMX42SR
VM3
Switching from 3-axis to 5-sided
Easy transition to 5-sided workIncreases shop capability
VTXU
VMX42SR
VM3
Switching from 3-axis to 5-sided
Easy transition to 5-sided workIncreases shop capabilityMakes the jump to full 5-axis
easier & less scary
VTXU
VMX42SR
VM3
Switching from 3-axis to 5-sided
Workholding…but I can only hold one part at a time
Good
Better
…be creative
Operation 1
Operation 2
Part Part Part
Part
Part
Part
Programming 5-sided…how easy is it? …can I do it?
What is Universal Rotary?
Designed to operate on any 4 or 5-axis Hurco
machine
Control determines the necessary rotary
movements
Only one Part Setup
All rotations are incremental from original WPC
Fast & Easy!
Right Side
1. Move the origin point
2. Rotate the workplane
3. Program 3-axis
features
…It’s as easy as 1-2-36” x 6” x 6” Cube
Right Side
1. Move the origin point(1)
(2)
Right Side
1. Move the origin point(1)
(2)
Right Side
1. Move the origin point(1)
(2)
Right Side
1. Move the origin point(1)
(2)
Right Side
X
Y
Z
Right Side
Z
Y
X
Z
Y
X
Right Side
Z
Y
X
Right Side
Right Side