technologyspotlight

CAM for B-Axis Mill-Turn Machining

CAM for B-Axis Mill-Turn Machining

By Ann Mazakas Shops that invest in mill-turn technology need to know how to capitalize on the power and flexibility of B-axis capability for precise 5-axis milling. They also need to know how a CAM system can help them take advantage of this capability successfully. ESPRITs full 5-axis control is a complete, pre-configured CAM solution for multitasking machines developed in cooperation with machine tool builders and tested extensively at the factory level. ESPRIT unleashes the enormous potential for profitability of a B-axis mill-turn by easily handling the inherent programming challenges of these complex machines. B Axis for complete mill-turn integration Like traditional mill-turn machines, B-axis machine tools provide control over the Z-X (turning) and C (rotary milling) axes. These machine tools also give users control over the Y-axis for off-center milling operations. However, it is B-axis capability that sets these machines apart. The B-axis head is used as a milling spindle or a turning/ boring toolholder. The B axis is defined as rotation about the Y axis, and this fifth-axis positioning makes cuts with compound angles possible. B-axis capability gives a machine full support for fiveaxis index milling, 3D surface milling, and five-axis simultaneous milling. When outfitted with dual spindles, the extended machining range of a B-axis machine enables it to perform both milling and turning operations, on both the front and back of the workpiece.

Next Page

dptechnology.com

technologyspotlight

Turning + 5-axis positioning B-axis machines commonly produce cylindrical parts with milled features at compound angles or on multiple faces. Shops often use B-axis machines to manufacture shafts with slots, grooves and cutouts at compound angles. Shops also use B-axis machines for intricate, multi-faced parts, such as cutting tool bodies and holders.

ESPRIT lets you easily program the non-perpendicular multi-axis tool movements required to machine the intricate features and compound angles of medical components, complex valves, tool holders, oil drilling tools, and the like.

CAM for B-Axis Mill-Turn Machining

Tilt the B-axis to mill and drill at compound angles

Produce multi-faced parts with a variety of machining techniques

With a dual spindle machine, program on the front or back of the workpiece

The B-axis head holds turning tools as well as milling tools

Next Page

dptechnology.com

technologyspotlight

Turning + 5-axis simultaneous Watching a B-axis machine in action can be quite intimidating because of its complex configuration, simultaneous machining and non-perpendicular multiaxis tool movements. ESPRIT provides a fully integrated mill-turn programming environment to simplify the programming of these machines and provide shops with the flexibility they need to program B-axis parts efficiently and accurately.

A CAM package for B-axis mill-turn needs to provide a suite of machining cycles for two- through five-axis milling, including three-axis and simultaneous five-axis multisurface/solid machining, as well as support for turning cycles such as facing, boring, grooving and threading. ESPRIT gives programmers the flexibility to use milling and turning cycles in any combination in one session on a single workpiece: on the front or back of the part, with the primary or secondary spindle, with the upper B-axis head or lower turret.

CAM for B-Axis Mill-Turn Machining

3-axis milling operations are constantly aware of remaining stock for more efficient roughing

5-axis milling operations provide multiple strategies for tool axis orientation

Combine turning, milling, and precise 5-axis milling in a single setup

ESPRIT supports 5-axis contouring, finishing, swarf cutting, and impeller milling

Next Page

dptechnology.com

technologyspotlight

Work planes for B-axis positioning Work planes are an especially important tool for programming B-axis machines. ESPRIT uses the orientation of the UVW axes of a work plane to control the rotary positioning of a workpiece as well as the orientation of the tool axis. Work planes define the orientation of the C and B axes, so the drilling and milling of features at compound angles is easy. As a programmer creates machinable features in ESPRIT, each part feature is automatically associated with the appropriate work plane. With multi-face milling and drilling, automated work planes save time and make programming easier. For example, programmers can use a work plane to define the angles of the C and B axes to drill a hole at an angle, thus automatically rotating the Z-X coordinate system and requiring the programmers to specify only a single Z-axis move.
Feature recognition will automatically find the work plane from the direction of the selected faces of a solid model

CAM for B-Axis Mill-Turn Machining

Work coordinates for multitask machining For multitask machining, it is imperative to set the work coordinates correctly. In ESPRIT, the Turning Work Coordinates Add-is a standard function that does it all automatically Main Spindle Coordinate, Sub Spindle Coordinate, Tilted Milling Coordinate, Auto Run Mode, etc ...

As features and operations are created, they are automatically added to the active work coordinate

Next Page

dptechnology.com

technologyspotlight

Continuous B-axis turning A specialized lathe finishing cycle is capable of cutting continuously along inner and outer profiles in one step with just one tool, eliminating the need to use a series of turning tools with different geometries. The B-Axis Contouring cycle takes an efficient approach by continuously rotating the B-axis as the cutting tool follows the contour, allowing the tool to reach areas that would otherwise be inaccessible due to the tools geometry. This machining cycle reduces the number of cutting tools required, the number of tool changes and programming time while delivering a smooth surface finish. The B-Axis Contouring cycle is based on ESPRITs SolidTurn contouring cycle. The major difference is the B-axis technology that offers full control over the range of B-axis rotation during the entire cut. Plus, built-in collision detection prevents a collision between the part and the tool when the tool path is calculated. Programmers no longer need to create several programs using traditional methods. Instead, a single B-axis contouring operation will finish an entire profile without stopping for tool changes. Eliminating tool changes saves precious seconds in the overall cycle time and also eliminates the possibility of witness marks where one tool finishes and another begins.
B-Axis Rotation Strategies

CAM for B-Axis Mill-Turn Machining

Users can adopt two strategies to manage tool orientation throughout the turning operation. The first strategy is to maintain a constant lead angle between the tool and the workpiece surface. With this strategy, the tool always maintains the initial lead angle in relation to the profile being cut. As the slope of the profile changes, the B-axis head tilts the tool accordingly to maintain the same lead angle relative to the workpiece surface. The total tilt of the tool is limited by a user-defined range of lead angles in addition to the softwares automatic part/tool collision detection capability. This strategy produces the best cutting conditions by keeping the optimal angle between the tool and the surface being cut. The second B-axis rotation strategy is to minimize tool rotation by tilting the tool only when necessary. This strategy maintains the initial tool orientation until the tool reaches a surface that cannot be cut with the tool is in its current orientation. Only then does the tool tilt as much as necessary to cut the surface within the user-defined B-axis angle limits. This strategy limits the rotation of the B-axis to areas that cannot be cut at a traditional tool angle. Both strategies are easily verified and users can display tool-axis vectors on screen to determine the best strategy for a given part geometry.

Next Page

dptechnology.com

technologyspotlight

Solids-based verification of machine motion ESPRITs Machine Setup provides an interface for shops to define the configuration and number of turrets and spindles of the shops specific machines to ensure accurate simulation. Machine Setup allows the import of solid models for any component of a machine tool. Linear and rotary motion can then be assigned to machine components for a truly dynamic simulation of cutting operations.

Once the tool path is generated and verified, the postprocessor produces the G-code program for all milling and turning operations. This is an advantage over software requiring the user to postprocess turning and milling tool paths separately and then combine them into one program to download to the shop floor.

CAM for B-Axis Mill-Turn Machining

ESPRIT shows the workpiece on screen along with the key moving components of the machine tool (spindles, turrets, B-axis heads, tooling) in order to protect against potential crashes, especially during synchronized simultaneous machining or transferring of the part between the main and the sub spindle.

Next Page

dptechnology.com

technologyspotlight

Increase efficiency through automation A key for productivity is automation. An automated CAM system can be set up to guide the programmer in choosing the best machining strategies or it can be fully automated to determine and apply optimal machining processes. The level of automation should always be customizable. To help automate programming, ESPRIT offers knowledgebased machining (KBM). KBM enables the use of predefined processes that auto-adapt to the part geometry. Using KBM technology, the system will suggest tooling and processes based on predefined strategies. ESPRIT can interrogate a solid model and organize the geometry into machinable features. Next, the programmer can manually associates machining operations to the features or let the ESPRIT KnowledgeBase pick appropriate machining processes based on work previously done. As time goes by, the programmer increases and optimizes the machining library based on shop feedback. The knowledge becomes embedded in the software by capturing best practices. The more automated the process is, the more time and attention the programmer can focus on higher level tasks such as optimizing the program or improving the machine productivity. Partnering for success DP Technology has forged relationships with mill-turn machine tool manufacturers to meet the needs of shops using B-axis machines. This cooperation between machine tool manufacturer and CAM software developer offers significant benefits for shops purchasing B-axis machines because the solution offered saves a significant amount of software setup time, enabling shops to immediately take advantage of the productivity these machines offer.

For example, customers are assured of having a working postprocessor because the two suppliers have developed the postprocessors together and have tested them on sample B-axis parts. Further, the configuration of particular machines has already been defined in ESPRITs Machine Setup and is available right away. The potential of a B-axis machine for increasing productivity and producing multi-faceted parts in a single setup is a compelling reason for shops to invest the time and money in this type of mill-turn machine tool. There is now no reason to hesitate over concern about the challenge of programming these complex machines. Partnerships between machine tool builders and DP Technology ensure that a new B-axis machine will reach its potential because it has the necessary programming capability in place to maximize productivity.

CAM for B-Axis Mill-Turn Machining

DP Technology Corp. Phone: 1 800 627-8479 1150 Avenida Acaso Outside the US: + 1 805 388-6000 Camarillo, CA 93012 USA Email: [email protected] ESPRIT is a registered trademark of DP Technology Corp. 2011 DP Technology Corp. All rights reserved.

Go To Page 1

dptechnology.com