5 axis Reach: Part accessibility vs Rigidity...25 Specific case of bigger parts For bigger parts, a vise is not the solution Goal => To use the full surface of your table and your

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5 axis Reach:Part accessibility vs Rigidity5 axis Reach:Part accessibility vs RigidityYann PONSARD ‐ IMTS 2016Yann PONSARD ‐ IMTS 2016

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Yann Ponsard

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Birth place: Dijon, France

Height: 5’11”

Weight: Definitely too many crepes…

Hobbies: Food / Wine

SCHUNK: since 2007

Occupation: Vacations! (and sometimes Sales Engineer)

Status: Single

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Summary

1) What is 5‐axis machining and why? 2) Important thoughts to select your workholding3) Accessibility 5 axis4) Evolution of the Workholding and Safety5) Specific case of Bigger parts6) Tool‐Holding in 5 Axis machining

7) Questions/Answers

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What is 5‐axis machining and Why ?

‐ Remember that you are losing money when you are not machining parts

‐> Before, we only had 3 axis machining (Spindle AND/OR table movements on X/Y/Z only)

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With 3 axis machining the accessibility to your part is very reduced,

Multiple Setups => Wasted time/Less PreciseSometimes you will need different workholding systems to clamp the different faces of your part + Several tools

Opened doors = 2 minOpened doors = 2 min Opened doors = 2 min

Opened doors = 2 min

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WORK ENVELOPE

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5 AXIS = > 3 AXIS + ORIENTATION OF THE TABLE AND/OR SPINDLE

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3+2 machining 5 axis Simultaneous 5 axis Spindle only

+ : Cheaper/Add‐on/Easy programming

‐ : Longer cycle time / Smaller work envelope

+ : Precise / Very large space

‐ : Programming / Expensive

+ : Precise (datum) / Envelope / Unlimited special machining / Faster

‐ : Programming / Expensive

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With the different possible orientations, the 5 axis machine allows to finish a part in 1 or 2 OP (Setups)

More precise (always same datum) Faster (no multiple set up) = More parts = More MONEY !!! More accessibility Possible to get shorter tools (avoid breakage or vibrations)

Opened doors = 2 min Opened doors = 2 min

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BUT…………

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Having a Mercedes as machine does not mean that you will enjoy the ride, if you are equipped with square tires … A good workholding is the key for a good ride !

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Important thoughts to select your WH ?

‐What do I want to machine and how precisely?

‐Where and how can I clamp correctly (Rigidly) ?

‐How will the part react during and after the machining?

‐How do I want to load my part? Actuate my clamping system ?

‐How do I present my part to the spindle, to get the most accessibility?

‐Will I have interferences between my table, my spindle and my part?

‐ How do I want to switch from one kind of parts to another ?

‐What is my budget and what will be the ROI I can get with what I am buying?

‐What was the French guy’s phone number again … ???

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5 Axis machining ?

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Accessibility 5 axis

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0 degree

45 degrees

90 degreesSolution ? To raise up the part from the table !

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Accessibility 5 axisUsing a conventional vise is not the optimal solution for 5 axis…The part is not more accessible and the central axis of the part is not on the central axis of the table.

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Accessibility 5 axisSame kind of vise but we turn it into 5 axis machining by raising the jaws:

+ : It works, we can machine our parts!‐ : We’re losing a LOT of possible machining space !‐ : Less clamping force

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Physics explanation

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Evolution of the vise

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Evolution of vise designHigher jaws => More accessibilitySpindle closer to the part => More rigidityClamping force setup integrated => ConsistencySmoother spindle actuation => Avoid body injuries (tendinitis…)

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Accessibility 5 axisSolution with a self‐centering 5 axis vise + raiser

+: Small and compact design / Centered on the table‐ : Smaller stroke

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Evolution of the 5 axis Workholding and Safety

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CLAMPING AREA:Goal is to make it as small as possible (Higher clamping forces and better jaws and Press system are making it efficient)

However, reducing the clamping surface willead to an adaptation of your cutting specifications, in order to avoid vibrations.

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Other systems to raise up and clamp the part:Dovetail system + Raiser

+: Full accessibility on 5 faces‐ : Must machine the dovetail form underneath the part

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Other systems to raise up and clamp the part:

Clamping machinable Membrane

+: High clamping force / Small clamping surface / No deformation / No machining of dovetail necessary/ Precision‐: Limited clamping size => small parts

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By using a 45 degrees Pyramid (2 – 3 – 4 faces), you improve the accessibility AND the profitability of your application

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Loading/Unloading outside of the machine (using a quick change pallet system):‐Make sense for 5 axis machine (investment)‐ Very repeatable (0,005mm/0.0002”)‐ No cutting tools or sharp object around and appropriate environment/space outside of the machine‐ Less pressure on how quickly you have to change the part (it is now related to the machining time) => Less mistakes. ‐ Faster to change from one batch of parts to another

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Detection and communication between the workholding and the machine Air detection for part presence Detection for part correctly clamped Inductive detection for status of the workholding system (OPEN/CLOSE/CLOSED ON SOMETHING) Clamping force detection (value)

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Specific case of bigger partsFor bigger parts, a vise is not the solutionGoal => To use the full surface of your table and your current work envelope, without having to buy a new bigger machine for these specific parts.

If we can be proactive in the design, and add the possibility to clamp via pins = Direct mounting Full accessibility Very precise from machine to machine

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Specific case of bigger parts

Magnetic solutions:Very high clamping forceVery high parallelismNo power source needed during machining

Very popular in mold industry

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Specific case of bigger parts

3D machining with Vacuum system WHVery adaptable system for different shapes

Lower clamping forcePopular for Aerospace parts (Aluminum/Composite…)

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CONTACT

Tool‐Holding in 5 axis machining

The diversity of movements, the complexity of the parts, and the machining of deep cavities lead the tool‐holding world to evolve constantly.

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Different technologies are employed, but all of them have properties in common, for a real use of 5 axis machining:

‐ Rigidity ‐ Excellent run‐out / balancing (faster rpm)‐ Slim design


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Tool‐Holding in 5 axis machiningHydraulic system+: Precision / Vibration dampening/Easy to use‐: More expensive

Polygonal clamping system+: Very slim design / High speed‐ : Less rigidity

Heat Shrink system+: Very rigid / High speed‐: Vibrations/Safety

Mechanical system+: Easy to use / Different diam‐ : Consistency/Vibrations

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Extensions => CombinationsBetter accessibility

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Steps to improve your green zone

1) Select the correct workholding / Raise your part2) Use Longer and slimmer tool‐holders3) Use extensions4) Use longer tool

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Any questions ?

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Yann PONSARDSales engineer Workholding Department

BOOTH W‐2000

[email protected]

+1‐919‐770‐3935

Merci beaucoup pour votre attention !

Documents

5 axis Reach: Part accessibility vs Rigidity...25 Specific case of bigger parts For bigger parts, a vise is not the solution Goal => To use the full surface of your table and your