5-Axis Technology that Matters

Dont Get Left Behind

CNC technology continues to accelerate. Its difficult to figure out what matters and what
doesnt when it comes to new features and new processes. Technology surrounding 5-axis
machining can be even more difficult to digest, especially if you dont have a 5-axis machining center yet.
This technical article distills the massive amounts of technology jargon to explain software features resident in a 5-Axis machining centers control that make the process more
efficient. We will also illustrate why shops all over the country are investing in 5-axis to
increase profit margins on parts they were producing on 3-axis machines.
In fact, the title Dont Get Left Behind originated from an interview with a machinist at
Triangle Precision who said, When we started doing 5-sided machining five years ago for
the parts we used to make on our 3-axis machine, I was like, Why isnt everybody doing
this? It makes everything so easy. If you arent doing this you are going to get left behind.
Cutting Tool Engineering Magazine, Multi-Axis Access January 2011.

Figure 1

Problem: Multiple Part-Zero Setups

Even an uncomplicated part that is five-sided requires multiple part-zero setups. You waste
time and compromise accuracy when you have to continuously flip the part to machine
each side. Doing the same part using a 5-sided process turns five setups into one.

Solution: Transform Plane

A software feature called Transform Plane (see Figure 1) simplifies 5-sided programming
and eliminates the hassle of setting up part zero five times. The technology does the work
so you can start making chips. You just need to locate one part zero and the remaining part
zero locations can be defined as incremental measurements from the original location.
Additionally, you can still program the geometry on each of the sides if youre programming
in an XY plane. Transform Plane basically changes programming on a 5-axis mill back to
2.5D programming that you would do on a 3-axis millyou dont need to worry about the
tilting or rotating.
How it works: The tool axis becomes the z-axis. The control calculates all the tilting and
rotating required.
hurco.com

8800.634.2516

Indianapolis, Indiana, USA

5-Axis Technology that Matters

Figure2

Problem: Redundancy in Posting a 5-Axis Program

Each time you re-fixture, you waste valuable time re-entering the distance from part zero
to the centerlines of rotation and then reposting the program.

Solution: Tool Center Point Management

If your control has a software feature such as tool center point management, you only have
to post the program once and machine the partno matter where it is in relation to the center lines of rotation on the machine. Tool center point management solves the problem for
CAM software. The CAM programmer generates the toolpath based on the part models zero
location. Therefore, you can post the program independent of where the stock is fixtured
on the tablea substantial time saver for a five-axis part.

Benefits
Faster setup
Less complex post processor (NC)
Save time reposting the program (NC)
How it works: the machine coordinates are uncoupled from the part coordinates, which
means you only need to find the top corner of the part and the machine knows where the
machine position is located in relation to the centerlines of rotation.
Problem: Complex and Difficult Post Processors
Solution: Tool Vector Input
CAM systems generally use tool vectors to generate the toolpath. To make programs independent of the machines rotary configuration and to simplify the post processor, there is a
tool vector input control software feature for five-axis machining centers (see Figure 3).

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Indianapolis, Indiana, USA

5-Axis Technology that Matters

The Tool Vector Input feature lets you specify the tool tip location relative to the workpiece
and the tool axis vector instead of using address letters to specify the B and C axes angles.
Executing the program is much faster because the post doesnt need the machine configuration and the centerline of the rotary axes. Tool Vector Input allows the control to compute
machine angles and positions, and calculates the angle the tool is going to tilt from the
contact point of the surface.

Figure 3

Benefits
Scheduling flexibility (the program can run on another 5-axis
machine with a different axis configuration)
Simplifies post processor
The control computes machine angles and positions
How it works Because CAM systems generally use tool vectors
to generate the tool path internally, Tool Vector Input allows the
machining centers control to accept the vector code so the CAM
system doesnt have to filter the code through a post processor.
The control lets you specify the tool tip location relative to the
workpiece and the tool axis vector instead of using address
letters to specify the A, B and/or C axes angles. The controls
software automatically compensates for the position of the tool
using part coordinates that are relative to the centerlines of
rotation for the B and C axes.
Therefore, the control understands where the workpiece is located relative to the centerlines of rotation of the rotary axis.

hurco.com

8800.634.2516

Indianapolis, Indiana, USA

5-Axis Technology that Matters

Problem: Marks on the Part
Simultaneous 5-axis toolpaths can result in odd looping rotary moves that leave marks on
the part when the program is interpolated by the machines control.
Solution: Toolpath Linearization
A feature called toolpath linearization, which is specific to 5-axis, G-code (NC) programs,
eliminates the many line segments in the form of XYZBC or AC moves that a CAM
system uses.
Benefits:
Improved surface finish quality
Smaller NC programs
Eliminates gouging of the workpiece
How it works The tool tip and tool vector are interpolated between tool positions with
respect to the workpiece, even with the tool and part rotating inside the machine.
The tool tip basically attaches itself to the workpiece instead of blindly following the
rotations commanded

Figure 4

Figure 1

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5-Axis Technology that Matters

Figure 5

Reposting to Adjust for Tool Wear on 3-D Surfaces

For 3-D surfaces, you cut off of the tool centerline to get a
better surface finish. Oftentimes, you are forced to repost the
program because you need to adjust the tool diameter
for wear.
Solution: 3-D Tool Compensation
A software feature called 3-D tool compensation eliminates
the need to repost the program in order to adjust the tool
diameter to compensate for tool wear or tool substitution.
Benefits
Eliminates idle time caused by tool breakage
Compensates for tool wear
Flexibility and freedom in tool selection
Saves significant time compared to rewriting the program to
adjust for tool wear, tool breakage, and/or tool substitution,
and then reposting the program
How it works The 3-D Tool Compensation feature adds UVW,
which is the surface contact point of where the radius comes
in contact with the surface it is cutting. You only needs to
change the D (diameter) and R (radius) values of the tool. The
3-D Tool Compensation feature does the rest.

hurco.com

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Indianapolis, Indiana, USA

5-Axis Technology that Matters

Latest + Greatest
Automatic Safe Repositioning (ASR) is a control feature only available from Hurco. ASR
tells the machine to retract along the vector and override the out-of-limits protocol. No
stoppage. No error message. The software is smart enough to retract, move to Z0 along the
X-limit, re-orient the tool, move to retract plane, move above the plunge point, and plunge
to the target along the tool vector. An addition of one G-Code tells the machine to retract
along the vector and override the out of limits protocol. No stoppage. No error message. The
software is smart enough to retract, move to Z0 along the X-limit, reorient tool, move to
retract plane, move above the plunge point and plunge to the target along the tool vector.
Universal Rotary allows a part program to be used interchangeably on both types of Hurco
5-axis machining centers even though they have different configurations. You simply program how the tool rotates into position on the part, and the control instructs the machine
how to orient the axis to cut the feature.

Customer Corner: 5 vs 3
The five-sided software is very easy to use. On
our 3-axis machines we had six setups. On our new
5-axis VM10U, we only have two setups.
Gregor Technologies/USA

hurco.com

8800.634.2516

Indianapolis, Indiana, USA

5-Axis Technology that Matters

With our Hurco 5-Axis machining center, we went from 9 operations to 2 on this
military part. We save 40 minutes per piece in cycle time alone and easily save an
hour and 10 minutes total. Maybe even more important to our bottom line is the fact
that the operator is running two other machines while the VM10U is making chips,
EMM Precision/USA

The Hurco 5-axis VMX30U saved us 4,000 setups on just one part.

When the part was milled on the 3-axis

machine, five sides were completed in 8 to 10

hours, including repeated manual re-fixturing.

On our 5-axis Hurco, we can machine

the same part in three hours.

As only one additional set-up is needed

for machining the sixth face, the component is

produced in two milling operations followed by
sparking. RST Engineering / UK

hurco.com

8800.634.2516

Indianapolis, Indiana, USA