5-Axis: The New Normal

Errol Burrell:

Thank you for joining us on IMTS Spark for the Okuma presentation on 5-axis titled "The New Normal."

Errol Burrell:

Today, I'm going to spend 10 minutes to provide you with an overview of some of the features and functions available on our 5-axis Okuma machines, and also how they will benefit you and make you much more productive. We'll have five minute Q&A after the video, and, please, I implore you to send in as many questions as you want. There's no such thing as a stupid question in our world. Please send them in. We look forward to engaging with you.

Errol Burrell:

So without further ado, we're going to crack on with the actual presentation. Thank you.

Errol Burrell:

Hi. Welcome to Okuma's IMTS Spark live demo, titled 5-axis: The New Normal. In these unprecedented times, the phrase "the new normal" is seen as very negative, but when used in context with the term 5-axis the meaning is seeing what's more favorably.

Errol Burrell:

In previous years, 5-axis technology was only mainly visible in large shops with huge financial budgets or in machine shops that produced so-called true 5-axis parts such as blades or impellers. Because of this, many companies at the time felt that 5-axis technology was out of their reach. Comments, such as cost, complexity, skill level, software, or we have no need for a 5-axis machine played a large part in people's reluctance to buy this technology. To be honest, a lot of the reasons were well-founded at the time.

Errol Burrell:

Now leap forward to the present day and the change in the industry is absolutely astonishing. The fact is, the majority of shops, such as BMW machine shop in Alabama, now possess a 5-axis machine, which is now seen by many of these shops as their mainstay. This is due to the fact that in most cases, 5-axis machine is seen as the most profitable, the most productive, hence the term, the new normal. With the support of my two Okuma colleagues, Kyle Klaver, Sales Engineer, Mark Hamielec, Senior Application Engineer, and myself, Errol Burrell, Machining Center Product Specialist, we will explain some of the functionality on the OSP control that makes the transition to a very 5-axis a very painless process.

Errol Burrell:

After the presentation, we'll open ourselves up to questions and answers. Enjoy.

Kyle Klaver:

Hello, this is Kyle Klaver and today I'll be talking about dynamic fixture offset and how it pertains to 5-axis machining. What is dynamic fixture offset used for on 5-axis machining? It is used for 3+2 machining. This is where a part can be set up and machined on five or more sides in a single setup. Dynamic fixture offset is easy and powerful.

Kyle Klaver:

By utilizing the 5-axis machining center with dynamic fixture offset, you can easily replace numerous machine setups with one 5-axis machine using 3+2. This dramatically eliminates mistakes, reduces WIP, and increases throughput. Okuma's dynamic fixer offset is easy to use. It's just the G-code at the beginning and the end of the program. Program your part to part zero, load your part, set your fixture offset using Okuma's Renishaw standard spindle probe, run your NC program, and the Okuma OSP will do all the work for you.

Kyle Klaver:

The dynamic fixture offset function tracks your work offset in any orientation. This makes your part more accurate and eliminates operator intervention. With today's true position call-outs getting tighter and tighter, this helps you hold those tight tolerances that are normally impossible to hold in multiple setups. In addition, NC part programs can now be used across similar configured machines, making your life easier, allowing you to concentrate on other challenges within your shop.

Mark Hamielec:

Hi, I'm Mark Hamielec, an Application Engineer at the Okuma Tech Center in Chicago. I'm going to talk about functions that are helpful while machining 5-axis features.

Mark Hamielec:

Total center point control or TCPC is a function that controls the movement of each axis by using the tool end offset and numeric position stored on that parameter page. This function basically determines how the tool center point moves along the workpiece as specified by the axis movement commands. While moving along its 5-axis path, the machine needs to interpolate both linear and rotary motion simultaneously.

Mark Hamielec:

The TCPC calculates the feed rate of each axis. So the tool center point moves along the part that is the specific feed rate. Since the rotational centers are stored in the control, they do not need to be considered when creating the cutting program. This makes possible any the changes to the setup. For example, when you change the tool or place a part on the table in a different location, you don't need to repost the program, as the TCPC figures out where it needs to be. The program is also universal for similarly- configured machines.

Mark Hamielec:

Tool posture compensation is coupled with Tool Center Point Control and enables minor axis inversions to be filtered while using TCPC via either parameter setting or G-code. Occasionally, the CAM program output may cause the tool posture to move erratically because of errors in linear approximation. This means that smooth cutting is difficult to maintain, and the result is a longer cycle time and a rougher surface finishing.

Mark Hamielec:

Using Super-NURBS function, the OSP control projects the tolerance band that is predetermined by the programmer to the series of points. Based on this, it will create a spline that is a best fit and may not require some of the points that are redundant to the spline path.

Mark Hamielec:

As a benefit, the user achieves smoother tool path, and with fewer points, the positioning feedback has less data to crunch, thereby accelerating movements while still maintaining accuracy. The result is controlled, high speed, and high-quality CNC machining. With faster roughing speeds and better surface finishes, hand polishing is eliminated so that part can be completed entirely in the machine.

Errol Burrell:

I'm Errol Burrell, Machine Central Product Specialist. In the next topic will be discussing 5-Axis Auto Tuning. The Okuma 5-Axis Auto Tuning performs two tasks, which are it calculates the machine's kinematic values, as well as the volumetric accuracy. The kinematic values are derived from the spindle gauge line, the tabletop, the center of rotation of the C-axis, and in this demo, the pivot point of the A-axis.

Errol Burrell:

To get started, we place a magnetic base with a 25-millimeter sphere on the table and with the probe, we calculate the exact center of the sphere. Now utilizing one of our 5-axis functions, we now transform the sphere to a new position. In this demo, we will rotate the C-axis 180 degrees, and the A-axis, roughly 35 degrees. In a new location we will now again probe the center of the sphere. Now, in theory, the zero values in the new position should replicate the zero values from the original or initial position. Please take into account, we're only talking about very fine margins. So, we will see a difference. Any difference that we do find is written directly into the kinematic table to compensate for any error.

Errol Burrell:

Back in the good old days, a task like this could take a highly skilled technician hours to perform. Now, an operator with minimal training can perform this task in minutes. One unique feature about the Okuma's 5-Axis Auto Tuning is the fact that it compensates for volumetric error in real time. This gives the operator the confidence that we can maintain a consistent, accurate machining process.

Errol Burrell:

I'm Errol Burrell, Machining Center Product Specialist. In the next topic we will cover some of the available options in a typical Okuma multitasking 5-axis machine. In this demo, we will take a look at some of the options that are available on Okuma's 5-axis platform.

Errol Burrell:

First: skiving. This function creates splines and spur gears. It does it by synchronizing the rotation of the C-axis and spindle, coupled with the splicing motion of the skiving tool to produce the perfect gear.

Errol Burrell:

Next is the oscillating grinding for those of you looking for a fine finish or looking to hold a tight tolerance. And of course, all the Okuma machines with this option are built with sealed way covers and excellent filtration. Or maybe you require turning. In this demo, we are featuring the MU-4000VL. It's equipped with a 1200 RPM table.

Errol Burrell:

Lastly, we will feature the in-process measurement. This option gives your operator the ability to generate a report or change tooling offsets as needed.

Errol Burrell:

Thank you all for taking the time to attend the Okuma's live 5-axis demo. Please feel free to visit Okuma's virtual showroom at www.Okuma.com/showroom. Thank you again.

Errol Burrell:

Now it's time for Q&A. Please feel free to ask any of our experts any questions that have arisen from this wide demo.

Errol Burrell:

So now we're open up to Q&A. So one of the first questions was from Altheus Coughlin, I hope I've said your name correctly. So as you can see, the line was actually programmed by one of our partners, OPEN MIND, using the hyperMILL software. We used shrink tooling and it took quite a bit, and it was quite an endeavor, but if you want one, you'd have to buy a machine. So with every machine you buy, you get one, particularly if it's one of our more expensive ones. But joking apart, we normally showcase these at trade shows or product trade shows. They're normally one of the most popular things to see at one of the trade shows. Everybody gathers around it and they're all asking questions about something they saw on a metals machine, not on a 5-axis machine. They are very beautiful.

Errol Burrell:

CJ Alza: which machine configuration is better for me, articulating head in the spindle or trunnion? It just depends. That's the question I hear all the time. You get table-table, head-head; it just depends on the type of parts coming in. Is it a heavy part? If it's a real heavy part, I would suggest a head type machine. So you're not rotating the actual part on the table too often. It just depends on the application before you make that decision on what type of configuration you're going to be using on the 5-axis machine.

Errol Burrell:

Ben Cross: I never got a lion. We'll get back to you on that, Ben, about the lion part.

Errol Burrell:

Chris Colton: the resolution. The resolution is a one-micron indicator. That's a 10-micron indicator.

Errol Burrell:

Oh. What size range of 5-axis machines do Okuma sell? Well, we start from a 400-millimeter pallet right up to one meter pallet machines. We do a nice wide range. So we have the MU range and then we have the MILLAC, the older forms, and then we also have our GENOS 5AX [GENOS M460V-5AX] is probably one of our most popular. It's considered an entry level, but not really. It's built to the same standard as all the MUs. It's just a much more affordable price. Thank you, Ben. I'm glad you enjoy your 5AX. I hope it's been very productive for you.

Errol Burrell:

Chris Colton: why can I not use a rotary table on a 3-axis mill instead of a 5-axis?

Kyle Klaver:

Absolutely we can do that.

Errol Burrell:

Yeah. We can do that on our MB platforms, the MB-56 or the GENOS 560s, or the GENOS range. We can use a Koma table. In fact, that's where a lot of the customers progress from. They progress from a 3-axis machine with maybe a two rotary or a one rotary table on a 3-axis machine, and normally they outgrow that. Maybe their parts are getting bigger, maybe they're running out of space, and a lot of the functionality in the integrated 5-axis is not available in that environment. But a lot of people still go with that, depending upon the actual application.

Errol Burrell:

On the GENOS, which again is probably one of our best-selling machines, the OSP control is more than capable of doing simultaneous 5-axis with a Koma or a Nikken rotary table on the machine.

Errol Burrell:

Yes, we do offer 5-axis on our double column machines. We have, they call it, a BC head. So the BC head runs simultaneously to one another. So there's your 5-axis. So, yeah. We do off that on our double column machines.

Errol Burrell:

Okay. So feel free to ask more questions. I'm going to leave this for a little minute, our website, but thank you for joining us today. Okuma has more live presentations that we'll be doing over the course for IMTS Spark. The next one will be on October the 15th, titled "Multifunction." And our machine shops can obtain a competitive advantage by combining operations and reducing non-productive setup times. So we'll see you there.

Errol Burrell:

You can see there's our website; have any questions, please feel free to contact us. Have a good day, everybody. Thanks for attending.