The focus here is not on reducing the number of setups, as the customer was interested in achieving a very tight tolerance.
This knuckle component from one of the faces has features to be machined in six different angles and on the other face features in one direction.
On a 5-axis machine this part needs to be done in two setups:
Setup 1 - Backside
Setup 2 - All marked features
For making this part a typical 4 axis setup we will have:
Setup 1 - Backside + approach angle 3
Setup 2 - Approach angle 1,2,4,5
Or depending the fixture we would like to use we will need to add one more operation.
The important thing with this part is that the reference bore is the central one. On a 5-axis machine we can produce all the linked features from setup 2 and ensure the best quality in this case.
On a 4-axis machine we will have to deal with alignment and setup errors.
In this case, with a 4-axis machine such as an a61nx and if we could make it in two setups, we may be able to use a square tombstone and fit four parts per setup.
On a 5-axis machine such as an a500Z we would be able to effortlessly produce two parts per setup.