Setting up tools
In order to realize the return on your investment as soon as possible, a multi-axis spindle needs to be spinning as much as possible. In other words, measuring, adjusting, inspecting or any general fidgeting with tools is best done away from the machine while the machine continues making chips. One of the first things a shop needs to maximize 5-axis performance is accurate 3D models of every tool holder for your CAD system. The tooling assembly has to be modeled as close as possible to how it will be put into the machine—body diameters, gage lengths, etc. There is so much movement and rotation that the chances of a collision are real and costly. The problem is, not all STP files are created equal. Imprecise models aren’t uncommon, especially for cheaper tools. Not only are these difficult to simulate accurately, but it makes adjusting and verifying more time consuming; worst case scenario, the programmer fingers through a catalog and draws the tools himself. Accessibility can also be an issue—how easy are the files to access and acquire? As with tool quality, you get what you pay for when it comes to models. Carefully consider model accessibility and accuracy before purchasing and consider ease of use on future projects. With models and tool lists done, the next important step is accurate measuring and verification of the predefined tool specs. The simultaneous actions of 5-axis machining require more strict control of gage lengths, as measured from the face of the spindle and body diameter. This is where offline presetters become indispensable.
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