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5-axis machining: What makes it amazing! Recommended solutions for achieving process consolidation and high-precision machining in die/mold production - now is the time to implement it in Thailand!
21/11/2023
Samurai Asia Editorial Department
"5-axis machining," is becoming a trend at manufacturing sites in Thailand. The reality is that there are still many sites which rely on manpower, but against the backdrop of soaring labor costs in recent years and increasing demands from customers for high levels of QCD (Quality, Cost, and Delivery), the need for efficiency improvement and process consolidation in manufacturing cannot be ignored. Many on-site staff in Thailand are interested in 5-axis machining, but have negative preconceptions such as "difficult to operate," "a high implementation barrier," and "requires specialized knowledge.”
Three of Japan's leading manufacturing companies have joined forces to advocate the advantages of 5-axis machining from the perspectives of machining centers, tools, and CAD/CAM (software).
CAD/CAM manufacturer CGS Asia held the "5-Axis Machining Seminar for Beginners" jointly with Union Tool and Yasda Precision Tools. These three companies have a longstanding history of jointly hosting seminars in various countries around the world, and this was the first time the seminar was held in Thailand.
CAD/CAM prevents accidents with simulation functions
CGS's CAD/CAM software " CAM-TOOL " dedicated to die/mold production is equipped with numerous functions that realize highly efficient and accurate 5-axis machining of die/mold without requiring specialized skills. One of the most critical aspects in 5-axis machining is the avoidance of machine and tool interferences. This software excels at maximizing the performance of machining centers and tools while preventing these interference accidents.
CAM-TOOL: Suitable features for 5-axis machining
・Machine simulation
Interference check of machine structure and stroke over check of each axis can be performed by CL-based system. GUI for 5-axis conversion provides consistent operability and minimal operating environment to prevent machining accidents.
・Smoothing function
This function adjusts the tilt/rotate axis gradually at the points where the tool posture changes rapidly during 5-axis machining. This allows the table to rotate smoothly, resulting in high-quality machining surfaces.
・Avoid interference
Avoid interference of tilt/ rotate axes is performed by utilizing a proprietary 5-axis algorithm that automatically calculates fixed tilt angles that do not interfere with each other.
CAM-TOOL can automatically create cutter paths for 5-axis machining by simply setting the tilt angle in the cutter paths of 3-axis machining. Its strength lies in the ability to easily create safe and high-quality 5-axis machining data that avoids interference without relying on the operator's experience or skills.
Union Tool's barrel tools maximize the advantages of 5-axis machining
Union Tool presented the following advantages of 5-axis machining from a tooling perspective.
・Shorten the overhang length
In 5-axis machining, tilting the axis enables machining with a shorter overhang length than in 3-axis machining, which leads to improved machining efficiency and less tool wearing.
・Avoiding zero velocity at ball tip
The "Barrel End Mill" is a tool designed for 5-axis machining and features a peripheral edge with a very large curvature. Utilizing this peripheral barrel R enables highly efficient finishing at dramatically larger pitches compared to ordinary ball end mills. The standard lineup includes three series: COVB, which can be used at small tilt angles and is ideal for areas with narrow interference area CSTB, which has a large barrel R and is ideal for straight and inclined walls; and CWTB, which has a large taper angle and is ideal for milling flat surface.
・Utilization of barrel tools
The "Barrel End Mill" is a tool designed for 5-axis machining and features a peripheral edge with a very large curvature. Utilizing this peripheral barrel R enables highly efficient finishing at dramatically larger pitches compared to ordinary ball end mills. The standard lineup includes three series: COVB, which can be used at small tilt angles and is ideal for areas with narrow intervals between interfering objects; CSTB, which has a large barrel R and is ideal for vertical walls and inclined surfaces; and CWTB, which has a large tapered half angle and is ideal for machining flat areas.
▲ Barrel end mills series
The tooling database "Tooling DB" in CAM-TOOL is linked to Union Tool's database of approximately 6,000 tool types, making it a highly convenient and compatible solution.
Yasda Precision Tools' 5-axis machining center combines high precision and high rigidity.
From the machine manufacturer's point of view, the features of YASDA's 5-axis MC were introduced based on the precautions that should be taken during 5-axis machining.
・Optimized machine structure for 5-axis machining
Yasda Precision Tools’ machining centers are renowned in Japan as the mother machines of machine tool manufacturing. The high positioning accuracy and repeatability of the linear axes, of which mating surfaces of guide ways have been carefully hand scraped, and equipped the rotary & tilting table with extremely high accuracy, manufactured in-house, realize high-precision machining to the maximum extent possible.
・Countermeasures against thermal distortion.
5-axis machining experiences significant thermal displacement changes compared to 3-axis machining, which can easily affect high precision machining. To counteract rapid machine thermal deformation, it is equipped with a “Thermal distortion stabilizing system.” By circulating temperature-controlled oil through machine body following reference room temperature, thermal displacement of each axis is minimized thus stable high-precision machining is realized.
▲ “Thermal distortion stabilizing system” that circulates heat exchange fluid throughout the entire machine body.
・No expert knowledge required to maintain machining accuracy
“Navi-CAL" is a proprietary software application that allows even inexperienced 5-axis machining operators to easily perform precision machine calibration work with simple procedure, helping to create programs which are often problems in 5-axis machining and stabilize machining accuracy.
▲ Image of high precision calibration by "Navi-CAL”
▲ “YBM Vi40” 5-axis CNC Jig bore
Continuing to provide the world with Japan's leading manufacturing technologies
A questionnaire survey of the seminar participants revealed a high level of interest in 5-axis machining among on-site operators in Thailand.
・Have felt the need for 5-axis machining... 90%
・Satisfied with the content of the seminar... 99%
・Want to have the seminar materials...95%.
“C&G Systems, Union Tool, and Yasda Precision Tools have continued to develop highly specialized and proprietary technologies in the fields of machining machinery, tools, and software. As the 2nd generation of Yasda Precision Tools said, “Experience the first-class to become the first-class“ we have been collaborating together with this common policy of continuously disseminating Japan's top-notch manufacturing technologies to the world. Through this seminar, we were able to sense the further potential of the Thai manufacturing market. We will continue to deepen cooperation among the three companies to provide beneficial solutions to our customers." (Mr. Kashiguchi of CGS)
▲ The members of the seminar sponsors
