The Challenges for CAM Systems and Users in 5-Axis Machining

The use of short cutters is a key feature of 5-axis machining. It significantly reduces the deflection of the tool, results in a better surface quality, prevents reworking and reduces immensely the number of electrode erosions. At the same time there are increasing requirements placed on CAM systems. Collision control and collision avoidance in particular are complex and time consuming tasks. The knowledge of a collision for a given point and tilt angle is important but useless if the collision cannot be avoided. The automated collision avoidance of a cutterpath, while keeping the machine dynamics and the respect of the given limitations, are strong challenges for today’s CAM systems. Although 5-axis milling machines and CAM systems with 5-axis capabilities have existed for many years, it is fairly recent that the two have been useful for the manufacture of Molds and Dies. Challenges facing 5-axis CAM programmers involve more than just making collision free 5-axis CAM cutterpaths. Users must constantly consider surface finishes. They must be aware of machine run-times, and how seemingly small options during programming can make significant differences in actual versus theoretical run times. Programmers must consider not only cutterpath calculation times, but also collision checking calculation times, in relation to all programming times.