Need help with 5axis programming ?

[Alir3za]

Hello everyone.

I have this part that I want to milling with 5axis machine (control: siemens 840D).

I need help with choosing best tool axis setting and the strategy.

Any help would be appreciated.

[Alir3za]

Anyone?

I want to machine that undercut.

[ChristopherMarion]

Hi @Alir3za 

Check the attached project.  First crack at it.  There is a small section in the bottom that I could not get toolpath, so I joined it with an on surface link.  I also couldn't get a tool much bigger than a 3/8" ball.

A bit of work in PowerMill Modelling to build a surface, but not difficult.  I also had to create a pattern to define the tool axis.  Hope this is at least a good starting point.

[Alir3za]

First Thank you @ChristopherMarion. This would my work much easier.

Can you tell me if the diameter of circle you created to use as tool axis curve is related to anything or not?

Second,I wanna rough this part a little bit with 3+2 axis operation before running finishing toolpath.I setup a workplane like attach picture to get a good angle then I want to write a program to rotate the C axis around Z with a tip radius tool. I would be grateful if you could help me with the right strategy and tool axis settings.

[ChristopherMarion · Accepted solution]

Hi @Alir3za 

I just used the edge of the part and created a composite curve. I then offset it inward until I got the tool axis to behave on how I want.  Trial and error really.

As for roughing this part.  The safest method is to remove as much material in 3 axis and then tip in different orientations in 3+2 using a stock model.  In you case, maybe do it in 90 degree segments or even 45 degree segments.  This would involve quite a bit of toolpaths, workplanes and boundaries.

I did it a bit different, just to show you some options.  If you look at the attached project, I first created some stock to just focus on the undercut groove.  Then I created the following toolpaths:

1. Rough Straight - 3d model area clearance to machine in 3 axis.
2. Rough 5 axis 1 - Swarf toolpath with multiple cuts leaving 1/8" stock on the undercut
3. Rough 5 axis 2 - Swarf toolpath with multiple cuts leaving 0.01" stock on the undercut
4. Rough 5 axis 3 - Projection surface finishing toolpath that machines along the pattern going from out to in leaving 0.01" stock.  You may even want to clone this toolpath with a smaller cutter and focus towards the bottom of the undercut.
5. Projection_Surface_Finishing - This is the toolpath I sent you the other day.

I ran this through Viewmill, and it seems doable.  I had a few warning of rapid moves into stock, but this warning can be misleading.

Hope this is a good starting point anyway.  I did this quickly, so I am sure you will put your own twist on it.

Love to see some finish pictures of this part.