Stepping up your 5 axis machining are clear and absolute advantages to production time and accuracy moving to 5-axis machining. Not only can the cutting tools move along the vertical axis and two directions along the horizontal axes, but the tool holder can rotate, and so can the part. This gives the machinist the ability to approach the part from any angle for shorter tool length and greater precision. Let’s look at stepping up your 5-axis machining by combining these precision movements with automation.

CAD/CAM

Many machine shops still utilize manual equipment because it is the best way to teach machining. The rhythm of your hands guiding the tool path creates a connection to the process that can only be experienced in practice. Manual equipment can also be used for small jobs or prototypes as well.

The capacity of a 5-axis machine is well-suited to the automated world of CAD/CAM systems. Designing the toolpath on a computer translates the CAD drawing into G-codes that a CNC machine understands. Computer Numerical Machines can run without an operator by moving the various axes on command in a sequence of detailed instructions.

The speed and quality of the CNC machining process create business opportunities not available with manual machining. Projects can be designed and loaded into the software to allow quick changeovers to new production runs. Many parts, even in small batches, can be run daily from new or saved designs.

Tool Changers

When considering the capacity for 5-axis machining to complete a finished part in one operation, it can be important to introduce different tools. A CNC machine is normally equipped with one tool, but holding a magazine of tools that can be installed into a spindle arm through an automated process is one more step to efficiency.

A machine does not have to be shut down to install a tool for a secondary operation. The program for a part can include instruction to move the arm over to the tool changer to deposit a current tool and load a new one. This is particularly useful with complex parts that require drilling or boring operations after the initial design is fabricated.

This does require tool design to be relatively easy to engage and disengage, as well as easy to centre before starting the operation.

Pallet Changers

An additional step to CNC machining automation is changing the work table which allows loading and unloading of both raw and finished parts from the machine. Pallets improve both safety and efficiency in CNC machines. Robotics can remove the human factor from the machining process altogether, but are much more costly and see their value in continuous assembly-line work.

Typically, rather than a machine operator placing the raw material for machining or removing the finished product, automated pallets are coded with machine G-code commands to become part of the machining process. Most automated systems only rely on the operator to load and unload the materials from the pallet once it is free of the machine. Picture a rotating or swing-arm style assembly beside the CNC machine that simply places an entirely new workstation in place. Within seconds of machining completion, a new part is set and ready for tooling.

With a reduced chance for human error and changeover between jobs, pallet changers add just one more level of automation to improve 5-axis machining.

It makes sense to consider automation to reduce the non-productive periods for your equipment. One factor to consider in adding these additional functions to your CNC 5-axis machine is the footprint needed on the shop floor. Working with your CNC machine supplier will identify the right equipment to begin with to allow the addition of integral automation in the future. Stepping up your 5-axis machining can start with the CNC machine, and then invest in further automation as business and budget allows. This may be faster than you think with dramatic increases in efficiency by moving from manual to automated 5-axis equipment.