gos whitepaper 5axis

s e r i o u s s o l u t i o n s

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DEMYSTIFYING 5-AXIS MACHINERY1.0

Like many manufacturing technologies, 5-axis CNC

machining has the potential to help users improve

productivity and profitability. However it’s not for ev-

eryone. So how do you know if investing in a 5-axis

machining center makes sense for your operation?

Obviously, much depends on the kinds of workpieces

you typically machine, the industries you serve, the

intensity of the competition, and the demands of

your customers.

Among the industries that rely on 5-axis machining

to produce complex parts or simply improve their

manufacturing efficiencies are: Aerospace, Aircraft,

Automotive, Firearms, Off-road Equipment, Motors-

ports, Medical, Oil Field, OEM Machinery, Wind Power

Generation, Marine and Die Mold. Additionally, any

large equipment or prototype manufacturers can also

benefit from 5-axis machining.

We often find that there is some confusion about pre-

cisely what 5-axis machining is, what it does and

what the benefits are for manufacturers. This paper

will address these issues and present real-world case

studies to give you the fundamental information you

need to determine if adding 5-axis machining makes

sense for your particular business.

DEMYSTIFYING 5-axis MACHINERY

5-AXIS MACHINING DEFINED

When manufacturers think of 5-axis machining, what

most often comes to mind is 5-axis simultaneous

machining, which means that all 5 axes are engaged

at the same time to perform complex machining of

such parts as turbine blades, impellers and aerospace

airframes. Machining these kinds of parts requires all

5 axes (3 linear and 2 rotary) to

move at the same time during

the cutting process to achieve

the desired geometry. Here are

a few examples:


above: impeller

above: turbine blades

TYPES OF 5-AXIS CNC MACHINES

There are three basic

types of 5-axis machines:

(1) Trunnion, or Table/

Table; (2) Head/Table; (3)

Head/Head. Vertical and horizontal milling-based

machines are available in all three configurations,

while vertical and horizontal turning-based machining

centers use only the head/table concept. In milling

machines the three configurations look like this:


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5-AXIS MACHINING DEFINED (CONT.)

Another form of 5-axis

machining is 3 + 2, or

5-axis positional machin-

ing. In this type of 5-axis

machining, one or more

of the X, Y & Z axes move

simultaneously, while the

remaining two axes are indexed into position and

do not move during that segment of the machining

program. In 3 + 2 machining the NC program rotates

one or two rotary axes into position and locks them

in place while the X, Y & Z axes perform the cutting

necessary to achieve the desired geometry. Typical

applications for 3 + 2 machining include aerospace

manifolds, and multi-sided and compound angle holes.

above: airframe structures

above: airframe structures

above: compound angle holes

above: head/table

below: table/table

left: head/head

below: multi-sided parts


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PROGRAMMING 5-AXIS MACHINES

Manufacturers new to 5-axis machining sometimes

express concerns about the complexity of program-

ming and how difficult it may be for their machine

operators to learn. They also worry about costly crash-

es if the programming is not performed correctly.

Programming Facts

It is true that programming simultaneous 5-axis

machining is more complicated than programming

3-axis machining due to the greater flexibility in tool

path options 5-axis machining offers. However, this

isn’t as daunting as it may seem. With the proper train-

ing, an operator with solid programming experience

can learn to program a 5-axis machine.

Most users of 5-axis machines use CAM software

for programming. Used with a high-quality machine,

operating system, spindle and rotary table, a good

CAM system helps insure optimum cycle time, excel-

lent part finish and overall quality. The most efficient

way to approach a part for 5-axis machining is to

break down the processes into 3+2, 4+1 and then

5-axis simultaneous toolpaths. All 5-axis machines are

most rigid when the rotary axes are locked in place,

which allows for Maximum Metal Removal (MMR).

The Okuma 5-axis machines sold and supported by

Gosiger work with all CAM systems, including industry

leaders Mastercam and Esprit.

Collision Avoidance

Crashes can be costly, both in terms of damage to

parts and equipment, and, of course, lost produc-

tion time. Obviously, with five axes in motion, the

opportunity for such incidents increases. The good

news is that 5-axis machines equipped with Okuma’s

Collision Avoidance System (CAS) take the worry out

of machine crashes, and significantly reduce set-up

time. By entering 3-D model data for the workpiece,

tool, chuck, fixture, headstock, turret and tailstock into

the THINC®-OSP controller, machine operators can

view a real-time simulation just ahead of the actual

machine movements. This allows them to check for

any interference or possibility of collision, and imme-

diately stop the machine’s movement prior to a crash.

During automatic operations, the controller reads

the machining program before beginning an opera-

tion and checks axial travel paths for interference


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while considering programmed zero-point and tool

compensation values. If it detects interference, the

system temporarily stops axial travel before a colli-

sion occurs. In manual mode, operators can rely on

Okuma’s proprietary Hairbreadth Stop capability to

avoid any collisions while setting up the machine.

DOES 5-AXIS MACHINING MAKE SENSE FOR YOUR OPERATION?

Although less than 5% of machined parts require

5-axis simultaneous machining, over 60% of parts

are machined on 5 sides, which means they are all

excellent candidates for 5-axis machining, or what

Gosiger and Okuma refer to as “Universal Machining.”

We’re all looking for ways to make parts and products

faster and better at a lower cost, and 5-axis machin-

ing of multi-sided parts does just that. The result is

improved productivity and profitability. So here are a

number of reasons why Universal Machining with a

5-axis machine is a sound financial decision:

1. Reduced Operator Time Per Part: Using 3-axis

CNC machines for multi-sided parts typically re-

quires considerable operator time to move the

part from one machine to another, and to set up

the parts in between machining cycles. Moreover,

each time a worker touches a part, it adds more

cost to the finished product. These are expenses,

not investments, because they add no value. They

simply drive up the final product cost, reduce profit

margins and make you less competitive. With true

5-axis capability, on the other hand, you can usu-

ally completely machine a part in one cycle with

little or no costly operator intervention.

2. Fewer Costly Fixtures & Tools: Because you are

machining in one operation with all five axes ac-

tively engaged in the cutting process, you typically

eliminate many tombstone, special, top tooling and

rotating tooling fixtures. That, alone, can save thou-

sands of dollars. Moreover, using fewer fixtures

reduces the potential for part tolerance stack-up

errors, and 5-axis machining requires fewer special

tools and tool extensions, and increases tool life.

above: fewer special tools


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3. Greater Flexibility & Increased Spindle Usage:

As your customers’ requirements change, a ver-

satile 5-axis CNC machining center enables you

to quickly set up and make new parts, whether

simple or complex in nature. With this kind of

flexibility, the 5-axis machine spends more time

making complete parts, rather than waiting to

perform only a fraction of a machining opera-

tion. This capability also makes you better able

to service customers with Just In Time (JIT) and

KANBAN programs.

4. Reduced Floor Space Requirements: One 5-axis

CNC machining center can perform the work of

multiple, dedicated machines. For example, some

5-axis machine users have eliminated one or more

lathes, vertical machining centers and horizon-

tal machining centers. Think of the floor space

you can put to better use or eliminate entirely

by replacing 4 or more machines with one 5-axis

machining center.

5. Lower Inventory Investment: To meet your cus-

tomers’ JIT demands, many manufacturers using

3-axis machining for multisided parts find they

must carry a significant inventory of partially

machined parts. This work-in-process (WIP) ties

up capital and adds to overhead. Because 5-axis

machines produce finished or near finished parts

in a single cycle and in a shorter time, you can

reduce WIP and relieve the strain on your cash

reserves or lines of credit.

6. Makes You More Competitive: Even if you don’t

currently need 5-axis simultaneous machining,

the ability to handle complex parts allows you

to bid jobs in industries that may not have been

open to you previously. For example, workpieces

requiring compound angles or part features such

as cutting a constant radius along a tapered wall

can only be done on a true 5-axis CNC machine.

Additionally, the reduced cycle time means you can

more quickly turn around orders for a customer

who might otherwise go elsewhere.

above: high efficiency tooling


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JUSTIFYING THE COST OF INVESTMENT

As conscientious business people, we need to translate

the many advantages listed above into financial terms.

Although we can’t quantify the impact of every one of

these factors, we can offer the following illustration

comparing machining a six-sided prismatic part on

standard, 3-axis machines and on a 5-axis machining

center. Depending on the print feature requirements,

processing on a 3-axis machine requires four to six

operations, versus one or two operations on a 5-axis

machine.

Existing Manufacturer Process: 3-Axis Machining Center, 8K RPM, 9 operations

Equipment QTY Cost Each

ExtendedCost

Vertical Machining Center

6 $150,000 $900,000

Fixtures 6 $3,500 $21,000

Dedicated Tooling Spindle

20 $400 $8,000

Dedicated Employees 6 $80,000 $480,000

Total Cost $1,409,000

5-Axis Process: Okuma MU-400VA, 5-Axis Machining Center, 8K RPM, 2 operations

Equipment QTY Cost Each

ExtendedCost

Vertical Machining Center

2 $450,000 $900,000

Fixtures 2 $5,000 $10,000

Dedicated Tooling Spindle

5 $400 $2,000

Shared Employees 2 $80,000 $160,000

Total Cost $1,072,000

TOTAL SAVINGS: $337,000


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JUSTIFYING THE COST OF INVESTMENT (CONT.)

Clearly, there are significant, immediate financial

rewards inherent in 5-axis machining, along with

improved product quality, quicker turnaround for

customers, improved throughput and spindle utiliza-

tion, and reduced floor space requirements.

*NOTE: The numbers used in the above examples are

generalizations for illustration purposes only. Individual

results will vary depending on the actual costs of the

items included. A Gosiger 5-axis machining specialist

using your specific information can help you determine

the potential savings for your operation.

WHICH 5-AXIS MACHINE IS RIGHT FOR YOU?

If you decide that investing in a 5-axis machining center

is the right move for your operation, the next step is

to determine the kind of system that best fits your

unique requirements. That’s where the applications

experts at Gosiger can help. As a nationally respected

machine tool provider with an unequalled technical

service and support staff, we can help you analyze your

process and recommend the Okuma 5-axis machine

that best suits your needs.

Standard Part Processing

HMC $425,000

Tombstone (special) $40,000

Top tooling (fixture) $10,000

Spindle tooling - dedicated $30,000

Employee - dedicated $125,000

Total Cost $630,000

5-Axis / Universal Part Processing

HMC $425,000

Tombstone (special) $3,000

Top tooling (fixture) $3,000

Spindle tooling - multi-use $30,000

Employee - shared $30,000

Total Cost $491,000

CAPITAL COST REDUCTION: 28.3%


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Vertical Mill

• MU-400VA• MU-500VA• MU-6300VA – NEW MODEL!• MU-10000H (table/table

A/C) – NEW MODEL!

Vertical Mill with Turning

• MILLAC 330TU – NEW MODEL!• MU-500VAL• MU-6300VAL (table/table A/C)

– NEW MODEL

Horizontal Mill

• VH-800• VH-1000 (table/head B/A)

Double Column Mill*

• MCRB-III (head/head C/A)

Horizontal Multifunction Lathe

• Multus• Macturn (spindle/axis head

C/B)

Vertical Multifunction Lathe

• VTM80-YB• VTM1200-YB – NEW MODEL!• VTM200-YB (C/A)

Millac 8535X PF

For complete specifications on all Okuma 5-axis ma-

chines, contact Gosiger or visit www.Gosiger.com

Note: Work heads on select Okuma Double Column

machining centers are changeable. Vertical, fixed angle

or 5 axis simultaneous C/B heads are available. This

allows for maximum rigidity and accuracy to meet

your precise requirements.

Gosiger would like to thank Okuma 5-Axis Product

Specialist, Kyle Klaver, for his invaluable contribu-

tions to this paper.

THE COMPREHENSIVE OKUMA LINE OF UNIVERSAL MACHINING SYSTEMS INCLUDES:

gos whitepaper 5axis

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