How to use different tools and methods to optimize five-axis machining?

Release time:

2022-08-15

Using five-axis machining can provide many benefits in several ways. By analyzing equipment, processes and fixtures, especially tools and cutting effects, we can benefit from this. In addition to completing some features through full five-axis machining, the CNC tool optimization scheme can also selectively simplify the machining process using five axes. It includes the use of three plus two axes, or sometimes only three axes, especially for various roughing, semi-finishing and milling processes.

Using five-axis machining can provide many benefits in several ways. By analyzing equipment, processes and fixtures, especially tools and cutting effects, we can benefit from this.NC Tool Optimization SchemeIn addition to completing certain features through full five-axis machining, the machining process using five-axis can also be selectively simplified. It includes the use of three plus two axes, or sometimes only three axes, especially for various roughing, semi-finishing and milling processes. Although some part features have a hyperbolic profile and will move along five axes at the same time, by using the correct tool and maintaining an appropriate constant cut, almost any curvature can be effectively handled.

　　NC Tool Optimization SchemeThe main advantages of using five-axis machining:

Obviously, it can effectively obtain complex three-dimensional (double-sided) part features, not only with high precision, but also with excellent surface quality. Usually, only one clamping and a few cutting processes are required, the cutting time is greatly shortened, and the tool overhang is always kept as short as possible. In addition, the metal removal rate is usually improved, and the risk of tool collision is controllable. For five-axis machining, linkage machining and three-plus-two-axis machining, tool and process selection are key factors in achieving successful results. Compared with three plus two-axis machining, the process selection of linkage machining is more important, because the former is less challenging and can be regarded as three-axis machining. Five-axis CNC machining is based on the ability of machine tools to generate three-dimensional part shapes by moving in five axes. In addition, true five-axis machining means that in addition to positioning the tool along the axis of rotation, the tool can also be fed along these axes during the cutting process. The inevitable result is that the machine tool can form complex part shapes in one clamping. In addition to the three basic axes (x, y, and z), there are two additional axes (B and C, sometimes a and C, depending on the machine configuration) that rotate around the z and y axes (or x and y) during the cutting process. When the machine tool spindle or worktable is fixed at a certain angle and processed in a three-axis mode, it is three-plus-two-axis processing. From the point of view of the machine tool, there are many ways to obtain five-axis machining: five-axis machining center, ramp arrangement or through the spindle head attachment. NC Tool Optimization Scheme

Diamond milling solid carbide end mill five-axis linkage machining impeller mainly consider the particles produced by rotating tools on the surface of the part. Therefore, the cutting angle and inclination of the tool are realized by the CAD-CAM program and should be considered when designing the clamping mode. Not only the main deflection angle of the cutting edge will have an impact, but also the tool feed and return angle will also have an impact, thereby avoiding back cutting. NC Tool Optimization Scheme

The cutting angle can be measured according to the angle between the tool center line and the vertical line perpendicular to the surface of the workpiece in the feed direction. In many cases, this value will remain the same and conform to the recommended value of the tool used, but it can also be changed programmatically if the cam allows it. At a fixed cut-in angle, the tool can be inclined at a predetermined angle relative to the surface of the part in the entire feed direction. The cut-in angle is based on the small inner diameter on the surface and the effective diameter of the cutter.