Simultaneous 5-Axis: Serious Machining for Cutting-Edge Manufacturers
Errol Burrell 06.11.2021
Has the term simultaneous 5-axis machining or a 5-axis demo video captured your attention? Have you found yourself asking the question "what goes into the process of simultaneous 5-axis machining?" We're here to help answer your questions and explore how this innovative process can benefit your shop.
The Concept of Simultaneous 5-Axis
First, what is simultaneous 5-axis machining? This machining process involves moving the cutting tool and workpiece utilizing the X, Y, and Z linear axes and rotating two of the three A, B, or C axes simultaneously during a machining operation.
Aggressive Machining Capabilities
For shops looking to stand out from the crowd, capitalizing on the capabilities of 5-axis machining can elevate your reputation quickly. There are immediate ROI factors such as reduction of machines on the shop floor and quicker cycle times by eliminating tedious setups and movements between machines. Additionally, the larger, more profitable return comes with the ability to consistently secure jobs that call for niche, highly-specialized parts for industries and customers that require close tolerances.
Making the Shift to Simultaneous 5-Axis
For manufacturers which have not worked with 5-axis machines before, there may be some uncertainties about embarking on the adoption of this technology, which is understandable. Rest assured, if your shop is currently utilizing Okuma’s OSP operating system, you will quickly realize synergies, as the graphical user interface (GUI) and controls remain the same with the model progression of our machines. And if your programmer is well versed in 3-axis CAM programming, making the upgrade to a 5-axis machine takes minimal training – which is oftentimes available through Okuma or your local distributor.
3+2 DOES NOT EQUAL 5-AXIS
3+2 machining, often times referred to as “positional 5-axis machining” should not be confused with true 5-axis machining in which all 5-axes are operating at the same time. Contradictory, within a 3+2 machining strategy, the rotaries are only used to position and lock the part. Once the part is fixed, the X, Y or Z axes are then utilized as an independent step in the process. While 3+2 works well in many cases, its utilization can be limited when highly complex contours and shapes are required, such as our Okuma GENOS M460-V-5AX Leo the Lion demo.
CONFIGURATION FLEXIBILITY
5-axis machining grants extreme flexibility to a shop floor. With a variety of configuration types available including head-head, table-table, or head-table, it is easier to choose the variation that will enhance your current manufacturing process. Due to the unique orientation of the head to the cutter, 5-axis machine centers also increase your ability to use a variety of tooling including shorter cutting tools. This flexibility allows for higher cutting speeds without placing too much pressure on the cutter – ultimately extending the life of your tool. Specialized tooling for complex geometry for parts such as impellers and blisks also fit well into a 5-axis machine.
In addition to simultaneous 5-axis machining, there are additional features and configurations available within the machining scope that allow for adjustments to meet part requirements. For example, you do not have to use all five axes to get a great result; by locking one axis, a 5-axis machine has the flexibility to shift to manufacturing parts that may be better constructed using a 4-axis machining application. The same theory applies to using only 3-axes of a 5-axis machine – providing great versatility and programming options on a single machine.
AVOID COSTLY DOWNTIME
Another component critical to increasing ROI is eliminating unpredicted downtime and machine maintenance. Many shops choose to rely on the simulation within their CAM system or incorporate a collision avoidance system into their more sophisticated 5-axis machine tools to mitigate the risk of collisions between the tool, workpiece and other components operating within the machine tool. Software integrations, such as Okuma’s Collision Avoidance System, can help remove errors in your equations prior to cutting. This can help enhance productivity with less machine downtime, setup time, and trial cutting time. This one-time investment in enhancing your 5-axis machine’s intelligence will quickly cover its initial cost due to the savings in downtime and component repair or replacements.
Think simultaneous 5-axis machining can help your shop secure higher-margin jobs? Explore our in-depth 5-Axis Machining Guide or reach out to your local Okuma’s distribution partner to conduct an on-site evaluation to ensure optimal setup and performance of any Okuma machine.
