Multi-Axis Machining

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Multi-Axis Machining

• Manoj Mathew
• Scott Youmans
• Eric Klauser

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Overview

• Background
• Interview
• Equipment required
• Software
• Advantages
• Capabilities
• Industry application
• Case Study
• Economics
• Job Outlook
• Alternatives
• Questions?

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Background - Types

• Basics of CNC covered in this class
• 2.5/3 axis machines
• Screwing Machines (up to 7 axis)
• Articulating head machine (up to 7 axis)
• Mill-Turns (4th or 5th axis)
• Vertical Mill (4th or 5th axis)
• Horizontal Mill (4th or 5th axis)

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Interview Triangle Mfg.
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Equipment Required

• Live Tooling
• Mainly for the lathe
• Allows you to have milling capabilities on a
  lathe
• Live Head
• OD Milling Head
• Face Milling Head
• Rotary 4th and 5th axis
• Mainly for mill

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Software

• MasterCAM
• SurfaceCAM
• SolidCAM
• EdgeCAM
• Gibbs

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Advantages

• Reduced machining time
• Eliminates multiple setups
• Less setup time
• Less errors
• More complex geometries
• Holes and pockets normal to complex surfaces.

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Capabilities

• Tolerances
• American Machines .0005 - .001
• German and Japanese Machines .0001 - .0005
• Speeds
• Standard 50 5,000 RPM
• High End 12,000 RPM
• Weight
• Up to 500 kg

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Industry Application

• High tech industries (volume and precision)
• Automotive
• Medical
• Aeronautical
• Job shop investments

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Economics

• CNC equipment by its very nature is expensive
• Haas VF-2 is a 48,000 investment
• Add a 4th Axis brings that to 60,000
• Add a 5th axis brings it to 100,000
• Haas TL-15 is a 84,000 investment
• Adding live tooling with an additional axis is
  another 24,000

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Economics

• While machines can be as cheap as 100,000 this is
  for a very basic machine
• No tooling
• No options
• When a reputable machine is purchased it is often
  500,000 or more

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Economics

• Two Types of Labor
• 9.91 22.45/ per hour
• Programmers
• Operators
• Tooling costs are similar to conventional
  machining
• Jigs and fixtures reduced due to single setup

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Job Outlook

• Jobs in 2006 158,000
• Projected jobs in 2016 153,000
• 4 Decline

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Alternatives

• Parallel-kinematics machines machine
  tool-robots
• Strength of a machine tools
• Speed, flexibility, and precision of a robot
• Casting Processes
• Powder Metallurgy
• Rapid Prototyping

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Case Study - Weasler Engineering

• Mechanical power transmission products (gear
  boxes, drive lines, etc.)
• BeforeFour day lead timeFour
  operationsLots of scrap
• Excessive Work in Process
• 9-Axis Okuma MacTurn250W
• AfterParts machined in 14 minutes60 setup
  reduction costs
• Scrap all but eliminatedWIP minimized

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Questions?