Think Differently and You’ll Cash In On That New 5-Axis Machine Fast
Material Sourcing Let’s start with one of the most fundamental steps of making a part before we’re even thinking about machining: which material to source. Yes, 5-axis work can even be a little different here. Here’s just one scenario. While a square or rectangular billet will save some time when they resemble the shape of the finished part, the movements a 5-axis machine allows, provide more options. There are hidden savings to be found. Bar stock is less expensive, more readily available, and easier to hold than more frequently used billets. The material savings and ease of purchase will probably far outweigh the up-front cost. Getting Organized You’re in a higher stakes game with 5-axis machining. Don’t overlook your tool lists. Since the risk of collision is higher with 5-axis work, you should be using accurate 3D models of every tool holder in your CAD system. Body diameters, gage lengths, etc., in CAD should be as close as possible to how it will be put into the spindle. Do as much of this offline as possible; keeping spindles spinning is one of the best ways to realize return on your machine investment as soon as possible. Plus, using a ruler with 1/16 increments, trusting every spec or using inconsistent in-machine probes are not effective ways to measure when a couple of thousandths can make a difference like they often do in 5-axis machining. Tool presetters are a great tool for performing those measurements away from the machine, but they go far beyond simple measuring these days too. Presetter data can be connected to broader tool management systems and/or machines. They are the ideal setting for assembling tools and comparing them directly to a catalog, DXF or STP model given to the programmer.
According to the Association for Manufacturing Technology (AMT), orders for 5-axis machine centers grew 22 percent year over year—in the middle of the pandemic. Machine shops represent nearly half of all buyers. What those shops understand, or learned quickly, is that getting the most out of 5-axis machinery requires a little different approach; factors like holder interference, productively reaching into deep work envelopes and high-mix part changeover are just a few that come to mind. What can you do about it? How should you think differently? What equipment do you need if you’re adding a 5-axis? We have some answers.
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