This video shows the machining of a gearstick using 3-axis, 4+1, and 5-axis machining. The part also creates a smooth path and handles severe undercut regions on the shaft of the gearstick. The part is machined on a DMG 40 monoBlock machine.
In this part, the tool orientation is generally controlled relative to the machine, not to the part surfaces. The result, called surface-independent machining, produces 4+1 motion (one axis fixed) for most of the part. 5-Axis machines have many purposes, including multi-side machining and 4+1 (one axis fixed) machining. With one axis locked, the machine and control can quickly and accurately process high volumes of data. With fewer moving parts, the cutter life increases as does the surface finish. OPEN MIND’s hyperMILL® software as used to create the toolpaths for this components.
hyperMILL’s collision detection procedures can produce results that start with 4+1 machining motion, and then move into full 5-axis motion when necessary to avoid collisions. This collision avoidance routine greatly simplifies the programming task. The programmer provides a suggested angle and an allowable search range in the case when a collision is detected. In other systems, the programmer is seeking an ideal programming angle using trial and error processes.
Procedures as described above with collision detection and collision avoidance and of great benefit to new 5-axis programmers, that may be concerned about the complexity to program a part.
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