SINUMERIK live:

Programming dynamic 5-axis

machining directly in SINUMERIK
Operate

Basics, possibilities, and limits

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Unrestricted © Siemens AG 2018

Programming dynamic 5-axis machining directly in SINUMERIK
Operate – Basics, possibilities, and limits

1 Repetition of basics
2 5-axis transformation
3 Tool orientation
4 3D cutter radius compensation
5 Example workpiece live on the machine
6 Summary

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 1 Repetition of basics
Comparison of 3+2 and 5-axis milling

Common aspects: Difference:

3 linear axes (X, Y, and Z) 3+2-axis: static orientation of the tool

5-axis simultaneous: dynamic orientation of the tool
and

2 rotary axes (A, B, or C)

When is which used?

3+2-axis: roughing/preliminary finishing of 3D contours 5-axis simultaneous: final machining and finishing
Consideration of economic efficiency Workpieces with deep cavities or
(for most components on the market, frequent changes in curvature
3+2 machining is sufficient)
High surface quality
Tool and fixture making
Free-form surfaces (mold making)
Turbine and aircraft engine components
Structural parts (aviation industry)

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 1 Repetition of basics
Mechanical design of milling machines

Both for 3+2 axis and for 5-axis simultaneous machining,

two rotary axes (A, B, or C) in addition to the three linear axes (X, Y, and Z) are required for orientation of the tool.
Depending on the kinematics of the machine, these 2 axes can be set by a swivel head and/or a swivel table.

Head-head kinematics Table-table

Mixed kinematics
kinematics Mixed kinematics

Swivel head
and swivel rotary table

Swivel head
and swivel rotary table

Swivel head
and swivel rotary table

Swivel head Swivel head

rotary table Swivel head
rotary table
and swivel rotary table and swivel rotary table

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 1 Repetition of basics
Mechanical design of milling machines – example

Motion sequence for head/head kinematics

• Machine kinematics with rotary axes A and C in the head
• Semicircle in plane X/Y with linear axes X and Y
• Tool always perpendicular to the workpiece surface due to rotation of the tool through
180° about the Z-axis  C-axis
• Description of a semicircle (a circumference) with axes X, Y, and C

Motion sequence for table/table kinematics

• Machine kinematics with rotary axes A and C in the table
• Tool perpendicular to the workpiece surface  Rotation of the A-axis through 90°
• Semicircle by rotation of the C-axis through +90° in each case to -90°
• Description of a semicircle (a circumference) only with the C-axis

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 1 Repetition of basics
Mechanical design of milling machines – example

Motion sequence for head/head kinematics

• Machine kinematics with rotary axes A and C in the head
• Semicircle in plane X/Y with linear axes X and Y
• Tool always perpendicular to the workpiece surface due to rotation of the tool through
180° about the Z-axis  C-axis

Findings:• Description of a semicircle (a circumference) with axes X, Y, and C

• Completely different machine movements produce the same
result
• Movement of the tool tip and tool orientation relative to the
Motion sequence for table/table kinematics
surface are identical
• Machine kinematics with rotary axes A and C in the table
• Tool perpendicular to the workpiece surface  Rotation of the A-axis through 90°
• Semicircle by rotation of the C-axis through +90° in each case to -90°
• Description of a semicircle (a circumference) only with the C-axis

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 2 5-axis transformation
Simultaneous movement of the linear and rotary axes

Tool orientation:
Movement of the rotary axis for
orientation of the tool

 Tool tip moves along a circular

path How can this effect be avoided in
simultaneous 5-axis machining?

 Complicated calculation of the

Synchronous motion: axis movement would be necessary to
Linear interpolation of the rotary prevent this unwanted movement.
and linear axis

 Curved line

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 2 5-axis transformation
Solution: TRAORI

Tool orientation: Tool orientation:

Movement of the rotary axis for Movement of the rotary axis and
orientation of the tool compensating movements of the
linear axes for orientation of the tool
TRAORI
 Tool tip remains immobile in
 Tool tip moves along a circular
space
path
TRAORI enables convenient programming of
the tool tip, independently of the mechanical
design
Synchronous motion: Synchronous motion:
of the machine.
Linear interpolation of the rotary Additional compensating
and linear axis movements in the Z-direction
TRAORI

 Curved line  Straight line

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 2 5-axis transformation
Tasks of the 5-axis transformation

What does TRAORI do?  Kinematics and tool-dependent

NC programs.
• Transformation of the relative motion
between the tool and workpiece into
machine axis movements.
• Automatic calculation of the
compensating movements in X, Y, and
Z on a change in tool orientation
• All axes are interpolated
simultaneously

The TRAORI command activates the • Changes to the tool length and zero
5-axis transformation. offset
are considered in the program
sequence.
Position data now always refer to the tip
of the tool.
 NC programs only describe the The TRAFOOF command deactivates
relative motion between the tool and the
workpiece. 5-axis transformation.

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 3 Tool orientation
Linear interpolation ORIAXES

ORIAXES
• Command for linear interpolation = standard interpolation type
• Linear interpolation of the rotary axes synchronously with the
movement of the tool tip
• Progress of orientation depending on the machine kinematics
• Can be used if tool is not required to move along a precisely
defined surface in the WCS (e.g.: face milling with a ball
cutter)

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 3 Tool orientation
Vector interpolation ORIVECT

ORIVECT
• Command for vector interpolation
• Interpolation of the vector on the plane formed by the start and
end vector
• Changes in orientation due to movement of the rotary axes by
the shortest path
• Frequently for milling pockets with usually flat and inclined
walls

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 4 3D cutter radius compensation
2D cutter radius compensation to 3D cutter radius
compensation
2 ½ D cutter radius compensation = conventional 3D cutter radius compensation
Contour, center-point path of cutter
 2 ½ D (G41/42) • Activation of the 5-axis transformation  TRAORI

 Tool orientation always identical • Activation of the 3D cutter radius compensation 

CUT3DC/DF
• Compensation of cylindrical tool geometries:
• Shank-type milling cutter with and without corner
radius
• Ball nose end mill
3D cutter radius compensation = extension • Cylindr. die-sinking cutter
Continuous change in the tool orientation • Tapered die-sinking cutter
 Continuous change in the offset direction • Beveled milling cutter with and without corner radius
 Definition of the offset direction as a vector in space

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 4 3D cutter radius compensation
Difference between circumferential and face milling

CUT3DC circumferential milling CUT3DF face milling

• The direction of compensation is always perpendicular • Complex  No constant offset

to the plane on which the cutter is moving
• Compensation value and direction depend on the tool radius
and corner radius
• Tool orientation relative to the workpiece surface

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 6 Summary

Command for 5-axis transformation (TRAORI / TRAFOOF):

TRAORI enables convenient programming of the tool tip, independently of the
kinematics of the machine.

Orientation interpolations (ORIAXES / ORIVECT):

ORIAXES is the command for linear interpolation; ORIVECT, the command for vector
interpolation of the tool orientation.

3D cutter radius compensation (CUT3DC / CUT3DF):

The 3D cutter radius compensation takes the changing movement of the tool orientation
into account.

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