Top Seven Advantages Of 5-axis CNC Machining With HCNC CNC System You Can Expect
The Status Quo of the 5-Axis CNC Machine Industry
The 5-axis cnc machining industry is currently experiencing robust growth driven by increasing demand for precision manufacturing across various sectors, including automotive, medical devices, and energy. The adoption of 5-axis CNC machines has surged due to their ability to produce complex geometries with high precision, reduce lead times, and minimize the need for multiple setups. This technology allows for the machining of intricate parts in a single operation, enhancing efficiency and reducing the margin for error. The industry is also seeing advancements in software integration, automation, and digital twin technologies, which further optimize production processes.
However, the industry faces challenges such as the complexity of programming 5-axis machines, machine stability, vibration reduction, and tool wear management to maintain high levels of precision and efficiency.
What are the technical challenges of a 5-axis machine center?
- Programming Complexity: Creating toolpaths for 5-axis machining is significantly more complex than for 3-axis machines. The additional axes require precise control and synchronization, demanding advanced CAD/CAM software and skilled programmers.
- Collision Avoidance: With more axes in motion, the risk of collisions between the tool, workpiece, and machine components increases. Generating safe and efficient toolpaths that avoid collisions while maintaining optimal machining conditions is challenging.
- Kinematic Error: The complexity of moving multiple axes simultaneously can introduce kinematic errors, affecting the accuracy of the final part. Factors like backlash, thermal expansion, and mechanical wear can exacerbate these errors.
- Machine Calibration: Maintaining the precision of a 5-axis machine requires regular and meticulous calibration. Misalignment of any axis can lead to cumulative errors, compromising part quality.
- Thermal Stability: The heat generated during prolonged machining operations can cause thermal expansion in machine components, leading to inaccuracies. Effective thermal management strategies, such as cooling systems or temperature compensation, are essential.
- Tool Deflection and Wear: The multi-directional forces applied during 5-axis machining can cause tool deflection, leading to dimensional inaccuracies. Additionally, the complexity of the cutting paths can lead to uneven tool wear, affecting surface finish and tool life.
Top 7 Advantages of HMC series 5-axis CNC Machining with HCNC CNC System You can Expect
About our HMC series 5-Axis CNC Machining
Our five-axis machining center HMC series has the characteristics of high speed and high precision. The linear axis rapid movement speed can reach 60m/min. The A/C axis of the cradle turntable adopts torque motor direct drive, and the A-axis (maximum) speed is 80r/min. , C-axis (maximum) speed can reach 200r/min.
7 Highlights of HMC series 5-axis CNC Machining with huazhong 5 axis CNC controller
In addition, the CNC system is the strongest brain on behalf of the machine tool equipment, from the machine tool programming, electromechanical joint commissioning, RTCP parameter calibration, to the five-axis parts processing process optimization, on-machine measurement, remote operation and maintenance, etc., HuazhongCNC five-axis CNC Machining with HCNC CNC system, perfect solution to the technical challenges of the five-axis machine tool, to meet the international most advanced five-axis machine tool standards.
Highlight 1: Ultra-uniform surface interpolation function
Firstly, in view of the uneven length of the program section and the rotation angle of the tool, the G-code trajectory was smoothed at the end of the CNC system, which improved the smoothness and continuity of the interpolation trajectory and significantly improved the surface quality of the machined parts. Secondly, the feedforward is applied according to the accuracy model, and the follow-up error of each axis is controlled to near zero to improve the machining accuracy. Finally, the feed rate is adaptively adjusted according to the performance of the machine tool to improve the processing efficiency.
For example: processing Mercedes-Benz parts
- Processing purpose: To test the highly dynamic processing performance of machine tools.
- Standard requirements: smooth surface, no overcut.
- Actual effect: smooth surface, no overcut.
- Technical level: reaching INT level.
- Others: Feed adaptability can improve rough efficiency by 11%
Highlight 2: New RTCP technology
The new RTCP technology has RTCP functions for standard five-axis machine tools, six-axis machine tools, and seven-axis redundant degrees of freedom machine tools. It supports 100+ machine tool configurations, meets the precise control of position and speed in different processing scenarios, and improves processing smoothness. RTCP’s function of specifying the tool tip feed speed can improve program speed planning and significantly improve the efficiency of five-axis and above linkage processing of impellers, blades, composite material laying and wrapping and other parts.
Example: Processing S pieces
- Processing purpose: To test the comprehensive processing accuracy of five-axis linkage machine tools.
- Standard requirements: profile ≤±0.06 mm, smooth surface.
- Actual effect: contour ≤±0.02 mm, smooth surface.
- Technical level: reaching INT level.
- Other features: RTCP calibration takes about 5 minutes.
Highlight 3: CAM-CNC Fusion
The five-axis product package comes standard with Qianji CAM software, which supports universal three-axis, 3+2, and five-axis machining automatic programming; the supporting post-processing software can customize and generate processing programs according to the machine tool structure.
Example: Processing an impeller
- Processing characteristics: complex curved surfaces, difficult-to-process materials, and difficult deformation control.
- Machine tool requirements: high speed, high precision, and fast dynamic response.
- Actual effect: no deformation, uniform thickness, accuracy and surface quality meet requirements, efficiency similar to INT.
Highlight 4: Five-axis rapid calibration
Five-axis rapid calibration plays an important role in high-precision machining and efficient production, and is an important means to ensure the stability and accuracy of five-axis processing equipment. Five-axis rapid calibration technology has significant advantages in improving machining accuracy, shortening calibration time, reducing errors and costs, and enhancing equipment stability. It is an indispensable tool in modern high-precision machining.
- Purpose: Find out the relationship between the five axes of the machine tool and improve accuracy and efficiency.
- Effect: Calibration takes 5 minutes, and the data is stable at 3-5μm.
Highlight 5: Anti-collision
Machine tool anti-collision technology is an important tool in modern manufacturing to improve safety, precision and efficiency. It can significantly reduce losses, reduce costs, improve overall productivity, and enable machine tools to operate more automatically and intelligently.
- Purpose: To prevent equipment, workpieces and tools from colliding.
- Effect: Manual and automatic anti-collision can be achieved.
Highlight 6: Spindle thermal compensation
Spindle thermal compensation technology has significant advantages in ensuring machining accuracy, prolonging the life of tools and equipment, reducing scrap rate, improving production efficiency, etc., and is one of the key technologies in modern high-precision CNC machining. The HMC series of central China five-axis machine tools compensates for the thermal deformation of the spindle in real time by monitoring the thermal expansion of the spindle due to temperature changes to ensure machining accuracy and stability.
Highlight 7: Tool wear monitoring
Tool wear monitoring is a key technology that monitors the wear status of tools in real time to ensure machining quality and productivity. The HMC series uses a laser tool setter to monitor the breakage of the solid center tool.
Application of Five-axis CNC Machining With HCNC CNC System
It is suitable for five-axis linkage processing of impellers, precision molds, precision parts, and complex structural parts. It is mainly used in molds, turbine machinery, medical, automobile, new energy and other industries.
