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.
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
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.