Particularly Attractive Technology

Built-in simulation for collision detection is an essential feature for any 5-axis programming system. Simulation in Mastercam X6, for example, gives the user a complete view of part, tool, toolholder, and machine set-up, insuring that the program can operate safely at the highest reasonable production rates.

There has never been greater interest in 5-axis CNC machining centers. Manufacturers of all sizes, including small shops, have come to the realization that multi-axis machining opens doors to business opportunities that would otherwise be out of reach. In addition, the cost of these systems, although still very high (you get what you pay for), are within reach for any business that has access to enough work, not necessarily production, to keep this equipment cutting chips.

There are several reasons why this technology has become particularly attractive:

• Simultaneous 5-axis machining makes it possible to carve out what-used-to-be impossible amorphous shapes such as airfoils that are the basis of rapidly advancing 21st century technologies.
• Positioning capabilities allow 5-axis systems to attack, repeatedly, the machining of features in various planes from the most advantageous positions for breakthrough improvements in productivity. A recent video on YouTube shows the manufacturing of an aluminum engine block at Donovan Racing by relentlessly attacking the workpiece from different angles using high-speed 2D and 3D toolpaths. The rate of metal removal is so fast (250 lb in less than 2 hours) that the conveyors cannot haul the chips away fast enough.
• Elimination of multiple setups not only improves productivity and machining accuracy, while reducing labor and fixturing costs, but it also opens the door to lights out manufacturing opportunities. So even small shops can apply more spindle hours to higher value-added work without necessarily increasing staff.

With all that said, it is also true that the cost of today’s excellent 5-axis machining centers is still a shock to the system for those who ultimately purchase them. The potential advantages enumerated above will provide no consolation until the ultimate realization, which will be weeks or months after installation of the equipment. If only there were some sort of policy you could buy to ensure that the technology you have invested so heavily in will actually pay the anticipated dividends. The good news is that such insurance does exist: capable multi-axis CAM software.

Growing into 5-Axis
Most CNC users who first venture into 5-axis machining do not usually start out in a big way. They purchase a modest 5-axis machining center or simply add a rotary table to their existing 3-axis machine, which they then use for positioning to eliminate multiple set-ups, this type of machining is 3 + 2 indexing.

Many of these first time users do not give a great deal of thought to software. They have paid so much for their new equipment that they appreciate opportunities to cut corners a little and buy minimalist 5-axis CAM software with only the capabilities that they will immediately need.

In most cases, these users quickly learn that performing one 5-axis well leads to another. As the queue of work for their first 5-axis machine fills up and customers present them with opportunities that call for different envelopes or simultaneous 5-axis capabilities, the CAM software suddenly becomes a much more important consideration.

The best advice to give 5-axis CNC users is to choose CAM software that is highly capable and reliably protects and optimizes 5-axis investment, and is flexible enough to support company growth. To capture your position and future potential, ask questions as: What industries do you support? What materials are you comfortable working with? What cutting envelope are you comfortable working in? After a thorough and candid assessment of your strengths and aspirations, you will be in a much better position to make a thoughtful decision regarding CAM software for 5-axis machining.

If you wish to save money on 5-axis programming software, there is further good news. You may not have to buy your chosen CAM software all at once. Some of the best programs available are modular, allowing the user to purchase lower levels and fewer seats until the need for more extensive capabilities arise. When new 5-axis business opportunities appear on the horizon, these packages make it easy to move up a notch, capturing the new orders.

Once you have done some investigating about the nature of your business and its potential for growth into different types of 5-axis work, it is time to begin evaluating software options.

What to Look For
Here is a list that companies should consider when purchasing CAM software, whether they are first time users, or currently have many 5-axis systems in their shop:

The deisgn of expert 5-axis software packages, such as Mastercam Blade Expert, are to perform a unique set of very sophisticated cutting operations for complex manufacturing specialties that would otherwise have a prohibitively steep learning curve.

CAM vs. CAD Emphasis. CAD/CAM is a broad category of software that spans all of their virtual manufacturing activities, from the creation of models, to the output of code that drives CNC equipment. If they need software that allows them to do meticulous renderings of products with deep access to many components within complex assemblies, you need a CAD/CAM system with heavy emphasis on CAD. When it comes time to generate programs for precise and productive CNC manufacturing, they must turn to a CAD/CAM system that focuses on CAM. If you are in a product development role that requires you to work, frequently, back and forth between the part model and the manufacturing toolpaths, then it is important to have a CAM system with carefully written translators that facilitate fast and accurate transition between the CAD and CAM systems of your choice. You might also consider a heavy-duty CAM system that is resident within the design software so that you get the best of both worlds within a single CAD/CAM environment.

Big Toolbox vs. Expert Software. Some CAM products have limited feature sets that allow for crisp execution of programs because they consume limited computer overhead. This software appears excellent in demonstrations, but you may out-grow it quickly. Other CAM products offer a deep toolbox of capabilities that you can purchase all at once or in various levels as your 5-axis manufacturing requirements become increasingly sophisticated. This is the kind of 5-axis CAM software that most benefits manufacturers.

There are also expert CAM software packages designed to perform a unique set of very sophisticated cutting operations for such specialties as head porting or blade manufacturing. These CAM packages may be a good choice for manufacturers looking to get a foothold in complex manufacturing areas, such as head porting and blade manufacturing that would otherwise have a prohibitively steep learning curve.

Inside the Toolbox. If they are looking for software that will provide them with a growing portfolio of 5-axis capabilities, delve into the specific tools within the vendor’s software toolbox. All 5-axis software should be able to do roughing, finishing, and collision avoidance. Go deeper to see how execution of these essentials occur, asking:

• To what extent are features and toolpaths associative so that changes made in one area automatically adjust other areas of the program that are affected by these changes? Deep associativity eliminates countless hours of reprogramming and unfortunate manufacturing errors that result in scrap or machine damage.
• To what extent are toolpaths within the program capable of dynamic adjustment, allowing the CNC equipment to operate at optimal feeds, speeds, and depths of cut depending on the hardness of the material and the geometry being attacked? Dynamic features allow 5-axis CNC equipment to operate safely at the upper-end of the machine’s rated speeds for high productivity along with dramatically longer tool life.
• Does the software in question provide stock modeling and trimming capabilities, eliminating air cutting and improving productivity?
• If surface finish is an important consideration, then is it possible to refine specific areas of the toolpath to optimize finish and eliminate substantial amounts of grinding and polishing?
• How easy is it to obtain post-processors that will allow the CAM software to operate seamlessly with the 5-axis equipment on the floor, or with systems that may be purchased in the future? Can programs be written just once and posted cleanly to different machines as needed?
• What provisions does the 5-axis software make for collision detection and toolpath simulation to ensure that programs will run safely? In the 3-axis world, good simulation is important; in 5-axis, it is essential.

Vendor Commitment. The world of CNC 5-axis machining capabilities continues to evolve at a rapid pace. For example, dynamic machining approaches introduced only a few years ago are now providing users with productivity improvements approaching 50% in many applications. From the users’ perspective, these improvements have arrived on the scene suddenly. From the software developers’ perspective, these changes involved research and development efforts that took disciplined planning and execution at many levels for five years and sometimes longer. If you appreciate having a software vendor who will surprise you every year or so with capabilities that give you additional competitive advantages, look into their long-term commitment to R&D.

Stock modeling and trimming capabilities give users intuitive tools for editing the CNC program to reduce air-cutting time dramatically.

Support and Training. 5-axis CNC machining can be very productive and rewarding but it is far from easy to implement and use. Those who are successful have nearby access to help in the form of post-processor development, training, application problem solving, and advice on significant new features that will impact the kind of work they do, along with assistance in implementing them in specific situations. Are the local people offering the software under consideration capable and willing to give you that level of support, as needed?

How to Look
This article has provided a broad overview of the most important considerations for selecting 5-axis CAM software. Use it as a template for building a much more detailed item-by-item analysis of products they will consider. Search for 5-axis CAM software on the Internet. Visit the Forums to see what users are saying. Make sure you discount crank posts, there will always be some, no matter how reputable the vendor. If possible, talk with users at other companies that do 5-axis machining. What do they use? What do they like about it? What do they dislike? By all means, visit software vendors at trade shows. Demos at trade shows are fun to watch. However, the demo that will really tell you something is one using a part you supply that is representative of the type of work they currently do or wish to capture. Watch the vendor program one of these parts and then arrange to have it cut on the 5-axis equipment they plan to be using.

Individual pieces of 5-axis manufacturing equipment are far more expensive to purchase than the software used for programming them. However, the decision involving which programming software to purchase is just as important because it will help determine the ROI for 5-axis equipment purchases. The evaluation process must be as thorough and careful as you can possibly make it. If you go about this process methodically and with determination, you will arrive at a decision you will be satisfied with now and as your company grows over the years.

CNC Software Inc.
Tolland, CT
www.mastercam.com