A main feature of linked 5-axis machining is the use of short tools during the cutting process, which significantly reduces the stress bending of the tool, improves the quality of the machined surface, prevents rework and greatly reduces the use of electrodes. In 5-axis programming, people often pay great attention to the detection and avoidance of interference and collision. However, for the CAM system, these alone are not enough. The system must fully consider the kinematics and geometric constraints of the machine tool. This It is a strong challenge to the cam system.

5-axis applications and problems

The application of 5-axis machining in the aviation and shipbuilding fields has become increasingly mature, but its application in the field of mold processing has just begun. 5-axis machining is usually divided into fixed 5-axis machining (also known as 3+2-axis machining) and linked 5-axis machining.

During fixed 5-axis machining, the machine tool spindle will be tilted at a certain angle and shorter tools will be used for high-speed cutting, which not only improves cutting efficiency but also improves machining accuracy. Using this method, a series of area processing can be completed by setting multiple processing angles. Only one clamping is required to avoid the loss of accuracy in repeated positioning, which saves a lot of changeover time and reduces the number of electrodes used in subsequent electrical discharge machining. There are two important problems with multi-angle fixed 5-axis machining: First, the machining tool paths at different angles must overlap, which will prolong the processing time. The overlapping area will also inevitably produce tool marks, and the surface processing quality cannot be well guaranteed. Second, a series of angle definitions and programming are very cumbersome and complex, requiring programmers to spend a lot of time and increasing the risk of errors.

Linked 5-axis machining solves the problem of fixed 5-axis machining. Even if a very short tool is used, the machining angle will not be repeated. However, so far, there are still certain limitations in the application of linkage 5-axis in mold processing, which are mainly reflected in two aspects: First, there are relatively few linkage 5-axis machining strategies suitable for mold processing. This is because linkage 5-axis machining was mainly used in the past. Aerospace equipment and other products, parts processing, and these processing strategies are difficult to meet the requirements of mold processing; secondly, programming the linked 5-axis program requires high skills, and only on the basis of rich experience can accurate judgment and intervention be made . This is very different from 3-axis programming, and the corresponding technical talents in China are also scarce.

The same tool path can run smoothly on the auerbach ia 5 machine tool, but when it is switched to the dmc 75v, when the trajectory rises along the vertical wall, crosses the top surface, and then moves downward, the machine tool will generate an alarm

A new solution for 5-axis machining

The practical application of 5-axis machine tools and 5-axis cam series mold manufacturing is an advanced technology developed in recent years. As a world-renowned fully automatic CAM software, worknc has proposed a new and highly practical 5-axis machining solution for the first time in the field of mold manufacturing: worknc auto5. This solution can easily and automatically convert a wide variety of 3-axis and 3+2-axis tool paths suitable for mold machining into linked 5-axis tool paths, and automatically detect collisions and consider the constraints of the machine tool’s kinematic geometry.

WorkNC has a wealth of 3-axis and fixed 5-axis machining strategies for mold processing, and its excellent programming efficiency and operating performance have been repeatedly proven in the field of mold manufacturing. So can these advantages be utilized to the linked 5-axis? After years of research and development, sescoi has launched a new and highly practical 5-axis mold processing solution for the first time in the field of mold manufacturing. This is worknc's auto5. Using worknc auto5, programmers can simply automatically convert any worknc 3-axis or fixed 5-axis tool path into a linkage 5-axis tool path that is collision-free and meets the specified machine tool geometry and kinematic constraints. In addition, by setting parameters, the converted linkage 5-axis tool path can be smoothed to make it more in line with actual processing requirements, thereby ensuring processing quality.

A feature of the 5-axis machine tool is that the cutting state of the tool relative to the workpiece is the same between a swing axis defined between b9.5, c0 and b-9.5, c+180 or c-180.

worknc auto5 function module

worknc auto5 includes two functional modules: 3to5axis module and 5tomachine module.

The 3to5axis module can automatically convert 3-axis and fixed 5-axis tool paths into linked 5-axis tool paths according to the selected strategy. This module detects and avoids collisions between tools and tool holders. This conversion process does not depend on the geometric and kinematic characteristics of the machine tool.

The 5tomachine module automatically processes the linked 5-axis tool path output by 3to5axis based on the selected machine tool, detects and avoids collisions with the machine tool, and makes the tool path meet the geometric and kinematic constraints of the selected machine tool.

worknc auto5 cleverly solves the limitations of the application of standard 5-axis machining strategies and greatly expands the practicality of linked 5-axis machining in the field of mold processing. It inherits the efficient, automatic and simple programming concept of worknc's 3-axis programming. It becomes possible for existing programmers to quickly master the advanced technology of linked 5-axis machining programming.

worknc auto5 can control the swing angle of the tool axis by defining a peripheral drive line

worknc auto5 key technologies

There are many advantages to using linked 5-axis machining of mold cavities or related parts. However, programmers have always faced four key problems at the software level, and these problems have largely limited the popularity of 5-axis machining in the field of mold manufacturing. application. In response to these problems, worknc auto5 has proposed corresponding solutions to make complex 5-axis programming as simple and easy as 3-axis programming in the field of mold manufacturing.

1. Safety of linked 5-axis machining

Safety issues mainly refer to the collision and interference between the spindle and the workpiece or the machine tool table during the machining movement of the machine tool. Since the spatial running trajectory of the linked 5-axis tool path is difficult to grasp intuitively, most CNC programmers are "daunted" by the 5-axis machine tool. It is based on the strict definition of the geometry of the 5-axis machine tool and the collision relationship between the various parts of the machine tool. The collision interference detection function integrated in the software guides programmers to make appropriate judgments and operations, such as adjusting the axial direction of the tool axis in the area marked by collision so that it can avoid collision. If the modification of the collision area is missed, worknc auto5 will automatically delete the corresponding tool path to ensure the absolute safety of the 5-axis machine tool, related components, and processed workpieces during the entire processing process.

2. Machine tool geometry and kinematics constraints

In linked 5-axis programming, it is not enough to only consider the safety of processing. In fact, in linked 5-axis machining, overtravel problems of the rotary axis and the swing axis are far more common than collisions. Therefore, the tool path of the linked 5-axis must comply with the constraints of machine tool geometry and kinematics.

Most of the overtravel in 5-axis simultaneous machining comes from the angle restrictions of the rotary axis and the swing axis on the machine tool structure. In addition, for machine tools with a swinging spindle, when the spindle swings 90 degrees, it will be longer than the marked maximum stroke on the x, y, and z axes. Much smaller, this often happens with overtravel on the x, y, and z axes. These overtravels need to be checked in real time during programming, and the workpiece placement position can be adjusted internally through the software, reverse rotation can be added, or the machining process can be changed to avoid undue downtime.

The 5tomachine module of worknc auto5 can solve this problem very well: What needs to be explained is a feature of the 5-axis machine tool, that is, a swing axis is defined between b9.5, c0 and b-9.5, c+180 or c-180 The cutting status of the tool relative to the workpiece is the same.

Such complex problems sometimes cannot be handled in post-processing, but worknc auto5 can automatically solve them during the calculation process of 5tomachine. Worknc will define the travel limit parameters of each axis during the machine tool modeling process, read the shape and travel limit data of the selected machine tool during calculation, and automatically and quickly calculate a reasonable and safe tool path corresponding to the machine tool parameters.

3. Processing quality

In the aviation industry, linked 5-axis machining of large structural parts can satisfy the requirement that the tool is generally processed along the normal direction of the surface. However, what is pursued in mold processing is more about the details of the mold and the quality of processing. In this case, using the most common normal machining strategy in linked 5-axis machining will be counterproductive.

worknc auto5 can control the swing angle of the tool axis by defining a peripheral drive line. During the machining process, the tool axis is always perpendicular to this drive line and cuts around the entire workpiece, which greatly reduces the reduction in cutting efficiency caused by the frequent swing movement of the c-axis in each inner concave area, and improves the surface processing quality of the workpiece.

4. Rich tool path strategies

Nowadays, the linked 5-axis machining in mold processing is mostly used for contour processing, engraving and simple scanning processing. The lack of rich and effective tool path strategies has become a bottleneck hindering the promotion and application of linked 5-axis technology in mold processing.

The emergence of worknc auto5 breaks this bottleneck. Since worknc is originally a very mature automatic 3-axis programming software, it has more than 40 3-axis tool path strategies for mold processing, and auto5's 3-axis tool path automatic conversion and linkage 5-axis tool path technology is suitable for all 3 axes. Tool path strategy and provides 9 conversion modes. This allows worknc auto5 to convert more than 360 linked 5-axis tool path modes that can be used for mold processing.

5. Software operability

The efficiency of programming depends to a large extent on the operability of the programming software. Traditional linkage 5-axis programming technology is very cumbersome, and programmers need to consider too many factors. In contrast, worknc auto5 provides a humanized operating platform and is perfectly combined with innovative concepts and unique algorithms. As long as programmers have operated the 3-axis programming interface of worknc, they can program a 5-axis linkage tool path that meets the mold process requirements by clicking some additional buttons and options.

In recent years, high-speed milling has been widely used in mold cutting processing, which has greatly shortened the production cycle of molds, reduced mold production costs, and also brought qualitative improvements to the quality of mold processing. So what is the next technological hotspot in mold cutting? There is no doubt that it will be the application of 5-axis machining technology. As the cost performance of 5-axis machine tools continues to improve, 5-axis processing of molds will become more and more popular. This will once again initiate a technological change in the field of mold processing and lead the mold processing industry to cope with the market environment of global competition. WorkNC Auto5’s new mold 5-axis programming concept will also lead the development of CAM software technology in this revolution.