4- and 5-Axis simultaneous machining

EdgeCAM 4- and 5-Axis milling products are designed to meet the production machining requirements of industries such as aerospace, automotive, medical and oil & gas. 4- and 5-Axis simultaneous machining offers key advantages over conventional indexed 3-Axis machining:-

Reduced cycle time by machining complex components using a single setup. In addition to time savings improved accuracy can also be achieved as the potential for positioning errors between setups is eliminated.
Improved surface finish and extended tool life by tilting the tool to maintain the optimum tool to part contact point at all times.
Improved access to undercuts and deep pockets through tilting the tool or component allows shorter series tooling to be employed, further improving the surface finish and eliminating the need for secondary setups.

The ability to machine complex parts from solid that would previously have to be cast. This approach is highly beneficial for prototypes and small volume runs and is particular applicable with the latest Mill/Turn machines.

EdgeCAM offers a range of easy to use machining strategies designed to maximize these benefits.

4-/5-Axis machining in EdgeCAM
EdgeCAM offers a wide range of 4- and 5-Axis strategies which are all applicable to solids or surface geometry:

5-Axis SWARF machining is used to machine variable taper walls.

5-Axis finishing across multiple surfaces with control over lead/lag and side tilt angles.

5-Axis profile machining for slotting, de-flashing and trimming of sheet forms.

4-Axis rotary machining of automotive and aerospace components such as camshafts and crankshafts. This can also be used in the production of blades, rotary dies and tooling for the oil & gas industry. An advanced Run Tool option offers control over exactly which part of the cutter is used to engage the workpiece to give optimum cutting conditions and surface finish.

Other areas in which EdgeCAM’s 5-Axis strategies are applicable include the machining of impellors/turbine blades and engine port machining.

EdgeCAM seamlessly integrates 4 and 5-Axis simultaneous machining with 3-Axis milling environment allowing a mix of multi-axis and 3-Axis cutting strategies to be applied as required. A typical example would be 3-Axis roughing and semi-roughing, followed by 5-Axis finishing.

Multi-axis machining strategies are provided with an easy to learn, intuitive graphical interface to ensure fast programming of complex components. Each of the different options is supported with a graphical AVI representation to show its effect on the machining process. To aid clarity more advanced options are hidden unless specifically requested.

Automatic collision checking
EdgeCAM offers safe and reliable operation with automatic collision checking and avoidance.

Both tool and holder can be checked against drive and/or check surfaces, with EdgeCAM providing a full range of collision avoidance strategies including tilt to avoid, retract to avoid and remove toolpath. Different avoidance options may be deployed for the toolholder and shank.

Due to the limited space for cutter and holder, applications such as port machining can be problematic; advanced collision checking for undercut tools such as lollipop cutters offers valuable gouge protection.

Full machine simulation in every axis
EdgeCAM’s 4- and 5-Axis machining is supported by full machine simulation to aid visualization of the machining process and ensure safe operation. This is of critical importance in 5-Axis machining where small changes in tool orientation can result in dramatic rotary movements.

EdgeCAM Simulator ensures that the full machine tool model and all moveable axes are considered in simulation, verification and process optimization.
A fully detailed machine model may be created in an appropriate CAD system, such as SolidWorks®, Autodesk Inventor® or EdgeCAM’s own Part Modeler application. As an alternative to full modelling, an effective model of the essential machine tool components can be quickly constructed using easily defined parameterized devices including turrets, spindles and tools.

Instead of just collision checking between the component, the tool and fixtures, EdgeCAM’s machine simulation ensures that all of your machine tool is considered in simulation, verification and process optimization.

4-and 5-Axis milling offers huge advantages in the form of reduced lead time, improved surface finish and extended tool life. EdgeCAM’s powerful yet easy to use strategies for 4- and 5-Axis simultaneous machining can help you use your multi-axis machine tools to their full capabilities.