5axis white paper

5-Axis Technology that Matters

hurco.com 8800.634.2516 Indianapolis, Indiana, USA

Don’t Get Left Behind

CNC technology continues to accelerate. It’s difficult to figure out what matters and what doesn’t when it comes to new features and new processes. Technology surrounding 5-axis machining can be even more difficult to digest, especially if you don’t have a 5-axis machin-ing center yet.

This technical article distills the massive amounts of technology jargon to explain soft-ware features resident in a 5-Axis machining center’s 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 “Don’t 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 isn’t everybody doing this?’ It makes everything so easy. If you aren’t doing this you are going to get left behind.” Cutting Tool Engineering Magazine, “Multi-Axis Access” January 2011.

Problem: Multiple Part-Zero SetupsEven 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 PlaneA 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 you’re 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 mill—you don’t 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.

Figure 1



Problem: Redundancy in Posting a 5-Axis ProgramEach 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 ManagementIf your control has a software feature such as tool center point management, you only have to post the program once and machine the part—no matter where it is in relation to the cen-ter 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 model’s zero location. Therefore, you can post the program independent of where the stock is fixtured on the table—a 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 ProcessorsSolution: Tool Vector InputCAM systems generally use tool vectors to generate the toolpath. To make programs inde-pendent of the machine’s 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).

Figure2



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 doesn’t need the machine configu-ration 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.

BenefitsScheduling flexibility (the program can run on another 5-axis machine with a different axis configuration)Simplifies post processorThe 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 center’s control to accept the vector code so the CAM system doesn’t 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 control’s 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 lo-cated relative to the centerlines of rotation of the rotary axis.

Figure 3



Problem: Marks on the PartSimultaneous 5-axis toolpaths can result in odd looping rotary moves that leave marks on the part when the program is interpolated by the machine’s control.

Solution: Toolpath LinearizationA 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 qualitySmaller NC programsEliminates 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 1

Figure 4



Reposting to Adjust for Tool Wear on 3-D SurfacesFor 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 CompensationA 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. BenefitsEliminates idle time caused by tool breakage Compensates for tool wearFlexibility and freedom in tool selectionSaves 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.

Figure 5



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 pro-gram how the tool rotates into position on the part, and the control instructs the machine

how to orient the axis to cut the feature.

“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

Customer Corner: 5 vs 3



“ 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 set-

ups 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

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