Intelligent and efficient five-axis machining programming system

The advantages of improving surface accuracy, shortening processing time, and reducing the number of clamping times make 5-axis machining technology the most important component in the development of the current manufacturing industry. Therefore, its development has always attracted the attention of all manufacturers. In Europe, 5-axis machining has become quite popular, but it has developed relatively slowly in China. The reason is that software functions, program security and users’ technical experience are all important factors that restrict the development of 5-axis machining technology in China.

VeroSoftware is a company specializing in the development of CAD/CAM/CAE software for the manufacturing industry. The software product series covers the design and manufacturing of injection molds, cold punching dies, progressive dies and shoe molds, multi-axis laser cutting and wire cutting, etc., for Manufacturers provide integrated solutions. Currently, the products are widely used by more than 20,000 users around the world, covering most manufacturing fields such as automobile manufacturing, electronic industry, medical equipment, white goods, and aerospace. As an important part of the VeroSoftware series, Visi-5AxisMachining provides operators with a productive solution that uses advanced interference control to create efficient tool paths for complex 3D data, which will best satisfy modern Requirements for 5-axis machining technology.

VISI provides the industry with a unique 3D > 5-axis conversion function that can directly convert all 3D tool paths into 5-axis programs. This will greatly increase the number of already extremely rich 5-axis strategies to cover all possibilities. status. Using this approach will enable high-speed machining techniques to be applied to 5-axis tool paths. And this 3D > 5-axis conversion feature provides intelligent interference checking, automatically tilting the tool to avoid the workpiece when needed. This semi-automatic type of tool path will greatly speed up programming and shorten the learning cycle. The complete functions, rich processing strategies, and product system are easy to learn and use, allowing users of Visi-5AxisMachining to easily handle 5-axis processing of molds and products such as deep cavities, turbine blades, and propellers.

For example, in many complex molds, some deep cavities or cliff locations are often encountered. In traditional 3-axis machining, extended tools and rods have to be used, and even electrodes need to be removed for EDM processing. However, this not only increases The cost of processing increases the production cycle, increases tool deflection and multiple clamping errors, resulting in very low surface quality. By cutting at different angles, the spindle head can be lowered. Visi-5AxisMachining can effectively detect interference and automatically tilt the tool and tool holder to avoid the workpiece or fixture (see Figure 1). The main advantage of this strategy is the ability to use shorter tools, which increases tool stiffness and reduces vibration and runout. Constant cutting load and high cutting speed can ultimately achieve the effect of extending tool life and producing high-quality surface quality. When processing flatter areas, using a large-diameter bullnose cutter with a certain tilt angle can produce a smaller number of tool paths, thereby reducing processing time and improving the quality of the curved surface.

Figure 1 Visi-5AxisMachining can effectively detect interference and automatically tilt the tool and tool holder to avoid the workpiece or fixture

The machining of turbine blades and propellers has long been considered the standard for five-axis machining technology due to high surface quality, positional constraints and oblique movement of the rotation axis, and Visi-5AxisMachining provides all the necessary tools for the successful machining of such parts. . Visi-5AxisMachining establishes each continuous spiral tool path along the product with evenly distributed coordinates, allowing the tool to obtain the most regular and smooth contact, stable spindle load and the most constant movement of all 5 axes during cutting, thereby reducing Impact of unnecessary vibration on thin ribs.

In 5-axis machining, small movements of the tool may cause very large movements in each axis of the 5-axis machine tool, because each movement is amplified by the tool, tool holder and spindle. When interference occurs, Visi-5AxisMachining provides a variety of smooth axis motion methods to avoid interference. Interference avoidance strategies include strategies such as lifting the tool along the tool axis, tilting the tool for tool handle interference, and lifting the tool in a given direction that can avoid the workpiece. In addition to automatic interference avoidance, the rotation axis will also be limited to the movement range of the custom axis, thereby preventing the spindle from exceeding its travel.

In addition to traditional cutting simulation, Visi-5AxisMachining provides machine tool motion simulation specifically for 5-axis machining. Motion simulation can use the real machine tool dimensions and the rotation or movement range of each axis to conduct safety checks on the mechanism during the entire operation of the tool path. The over-cutting of the cutting tool and tool holder with the blank, fixture and any other parts on the machine tool will be graphically highlighted, and the rotation or movement of each axis will be detected for overtravel, allowing users to obtain the safest NC program.

There are various configurations of 5-axis CNC machine tools on the market, such as double swing of the worktable, double swing of the spindle, compound motion of table rotation and spindle swing, etc. VISI has a large post-processor library that can be applied to most machine tools on the market. In addition, all post-processors are fully customizable to suit different needs. For example, output CNC code for 3+2 axes or 5 axes linkage. By transmitting smooth and efficient CNC code to the machine tool controller, it will reduce unnecessary acceleration and deceleration movements on the machine tool, allowing the machine tool to run as close as possible to the programmed feed rate, which will help the machine tool operation. faster and prevents sudden direction changes, eliminating undue stress on the tool.

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