Shuttle Plate Machining on 5-Axis Centers: Process & Benefits
The machining center has become a “main force” in modern manufacturing. Its high machining precision, efficiency, and stability have led to its widespread use in factories, research institutions, and schools. The 5-axis machining center can process products with more complex shapes and more machining steps.
Five-axis simultaneous machining refers to a method where three main motion axes (X, Y, Z) and two rotating axes (usually A, C, or B, C) move together. This is used to process parts with complex curved surfaces, such as impellers, wings, and molds. Since it allows most, if not all, operations to be completed with a single fixture, it avoids the alignment errors associated with multiple fixture setups in 3-axis and 4-axis machining centers, improving the part’s accuracy and reducing auxiliary time.
1. Application of 3D Software in Machining
The operation of a 5-axis center is difficult to visualize using only the human brain, and manual programming for complex curved parts is not practical. Even if the machine is operated through manual programs, achieving precise dimensions is impossible. Therefore, CAD/CAM software is essential to achieve 5-axis linkage and help the tool find the correct position during machining.
We use Cimatron software for modeling and machining. It integrates CAD and CAM functions, ensuring no data loss when transferring the model to the machining environment. It supports 2.5-axis to 5-axis machining capabilities and meets the requirements for high-speed milling strategies. Cimatron software is user-friendly, intelligent, and improves programming efficiency. It also provides CNC simulation and can perform interference, collision, and overcut checks.
2. General Process for Machining Parts on a Machining Center
When machining parts on a machining center, the first step is to create a machining program, which serves as the machine’s operating instructions. The machining program is input into the CNC device, which controls the machine’s main motion: speed adjustments, start/stop, feed direction, speed, displacement, as well as actions like tool selection, workpiece clamping, and cooling. These operations are carried out in sequence, according to the parameters set in the program, to ensure the machining process produces the required parts.
3. Challenges and Solutions in Machining Shuttle Plate Parts
The shuttle plate is an important component of circular looms, mainly used for threading and guiding the yarn. In traditional machining, the process for manufacturing the shuttle plate involves several steps:
- Casting the overall shape.
- Grinding to smooth the shape and leave allowances.
- Milling the two sides and arc surface.
- Removing burrs and deburring.
- Clamping the plate for second milling and complex slanted surfaces.
- Precision milling of the shuttle head.
- Drilling straight and deep slanted holes.
- Cleaning and burr removal.
- Inspection.
After introducing a 5-axis center, we improved the process as follows:
- Cast the overall shape and leave 1mm allowance on the upper surface.
- Mill the two sides and arc surface.
- With a single clamping, the 5-axis center mills the complex slanted surfaces, drills slanted and straight holes, and taps threads.
- Clean the four bosses and remove burrs.
- Inspection.
Compared to the old process, the new process offers the following advantages:
The new process leaves a 1mm allowance on the upper surface, which is removed by the 5-axis center. This reduces the amount of grinding required and improves the precision and surface finish of the upper surface.
With single clamping, the 5-axis center can finish the upper surface, slanted surfaces, drill holes, and tap threads. This reduces the auxiliary time required for secondary clamping and eliminates alignment errors.
The new process is more concentrated, significantly improving machining efficiency and accuracy while maintaining dimensional stability.
4. Challenges in Five-Axis Machining of Shuttle Plates
4.1 Difficult Clamping and Positioning
The shuttle plate is large (472x126x111mm) and has a curved shape. The material is cast aluminum, which makes it prone to deformation under clamping forces. To address this, we designed a specialized fixture with a curved shape that matches the shuttle plate’s radius, ensuring stable clamping.
4.2 Interference and Collision During Machining
When removing the upper surface and slanted surfaces, software programming is used to achieve 5-axis linkage. Interference between the spindle and work table, tool holder and fixture, and tool and workpiece must be considered. We incorporated the table and fixture models into the Cimatron programming environment, allowing the software to automatically check for potential interference or collisions. After the program was generated, it was simulated to ensure there were no issues before actual machining.
4.3 Difficulty in Finding the Angle for Drilling Slanted Deep Holes and Risk of Tool Breakage
Then, rotate the A-axis to the set angle. Use low speed and feed during drilling. Ensure chips break effectively. Provide enough coolant to avoid tool breakage and maintain accuracy.
5-axis centers solve complex problems. They improve processes and enable new product development. These machines boost efficiency and accuracy. The shuttle plate in this article is one example. Processing it presents challenges. But with better technology and growing experience, solutions become easier. The value of 5-axis center will become more apparent over time.