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Prism Mould

High-quality surfaces through simultaneous 5-axis machining

The designs of injection-moulding part are becoming more and more complex, demanding 5-axis machining and high surface quality.

The benefits of 5-axis machining, e.g. shorter tool overhang length, can result in greater failures caused by two additional moving axes. Positioning failures, repeatability failures and CAM calculation tolerances are directly evident on the surface of the part.

However, the rigid machine structure of the Makino D200Z with its unique table kinematics and Pro6 control delivers a machined part with high-quality surfaces, and this eliminates the need for reworking or hand polishing after machining.
High-quality surfaces through simultaneous 5-axis machining

Specification of the Sample

Size  200 x 100 x 60 mm
Material  Stavax (50HRC)
Machining Time  13 hours 43 min
Tools  Ten tools of ten kinds
Surface roughness Ra  0.28 µm
Specification of the Sample

The unique Z table

The table’s compact and rigid design reduces vibrations and bending moments on the machine during axis movement.
Benefits of the inclined B-axis:
  • No change in the centre of gravity
  • Rotation at centre of work
  • Force loop minimised 
The light and compact design results in:
  • High rigidity
  • Good usability
  • No interference between spindle and table

Software – perfecting simultaneous movement

5-axis simultaneous movements put a great deal of stress on a machine tool. All 5-axis machines have to be perfectly synchronised and follow the NC program at the speed the CAM programmer set. In addition, there are a lot of imperfections coming from the NC program, such as errors in the 3D models and too few points for a perfect definition of the shape. That is why our D800Z uses the unique properties of Professional 6 to smooth up all these issues:
  • GI Scratch: Scans the NC code to look for imperfections that normally come from the 3D model, e.g. sewing errors between surfaces in the 3D data
GI Smoothing: Whereas traditional NC controls smooths toolpaths, Professional 6 smooths surfaces. The NC control scans the program and modifies it.