5축 가공기

2012. 8. 29 

박정환 

영남대학교 기계공학부

5축 가공 개요 

5축 가공기 

5축 가공 tool path 생성 

적용 사례 

◦ 자동차 사출금형 가공 

◦ 선박용 프로펠러 가공 

◦ 프로펠러 그라인딩 로봇 OLP 시스템 

전망 및 토의 

© 박정환, 영남대학교


© 박정환, 영남대학교 

3축, attachment 가공 

Positional 5-axis 

(고정형 5축, 3+2축, indexing work) 

Simultaneous 5-axis 

(동시 5축, continuous 5-axis)


Reduced set-up work 

◦ Eliminating extra fixturing & time 

Accuracy 

◦ fewer clamping & unclamping 

Better surface finishes 

◦ Shorter tools less tool deflection, vibration 

◦ Cutting condition (ball nose end mill) 

Machining complex parts 

◦ Undercut machining 

Time savings in hole drilling 

◦ 3+2 axis machining 


Ideal for machining deep cores and cavities 

High Speed Machining (all linear axis) 

Locked rotary axis mode rigid, accurate 

Simultaneous multiaxis work is inevitably less accurate than indexing work because the 

machine must be run in a loose mode with the rotary drives unlocked. (Apro 2009) 



From Secrets of 5-Axis Machining by Karlo Apro



3 linear axes + 2 rotary axes 

•Table/Table type 

•Head/Table type 

•Head/Head type 


Dedicated machine 

Robots (6- or more axis)


Tool with 

orientation 

Tool and workpiece 

with orientation 

Workpiece with 

orientation

Head/head machines 

(with long X- or Y-axis linear travel, 

but limited rotary axis travel) 

•Airplane wings and fuselage panels 

•Long extrusions 


From Secrets of 5-Axis Machining by Karlo Apro 

Head/table machines 

(with long X-axis travel) 

•Long rotary parts

Tilting head/Rotary table machines 


•Universal parts 


Table/table machines 

•Universal parts (not so big)


Gantry type head/head machines 4-axis machines 

•Large parts 

(aerospace, mold & dies, etc) 

6- or more-axis machines 


•Multi-faced indexing, 

rotational parts

RTCP (rotary tool control/center point) 

Optimum work envelope 

Feedrate for tool-tip points 

Post-processor 

Tool tip 


Workpiece 

Tool Centre Point Programming 

X




A = 0,30,60,90 

B = 0 

A = 0,30,60,90 

B = -90 

A = 0,30,60,90 

B = -30 

A = 30 

B = 0,-30,-60,-90 

A = 0,30,60,90 

B = -60

0 

L/G 


L/G 

L 

G 

F 

L/C 

L 

L/G/C 

a 

L: limit-over 

G: gouging 

C: collision 

F: feasible 

b 

180 

-30 0 30 

-180 

Feasible CL 

region 

Optimal (a,b) 

a 

Infeasible CL 

region


a CC 

a) Sturz-cut (a = sturz angle) 

a) Skive-cut b) Ruled-milling 

Figure 3.11 Sidemill UMOs 

b 

CC 

b) Plunge-cut (b = plunge angle) 

From Choi 1999

Active coordinate system (3+2 indexing work) 

Cut pattern control 

Tool axis control 

Tool tip control 

Gouge & collision avoidance 

Stock recognition roughing strategies 

Machine simulation 

Post processor 








Tool path plotting 

Cutting simulation 

Full machine simulation 

◦ Virtual machine building & G-code simulation 



Surface representation 

Machine strip estimation 

Optimal tool orientation and gouge avoidance 

Kinematic error 

Tool path topology (cut pattern) 

Optimal workpiece setup 


CNC Milling, Drilling 

Laser cutting 

Water-jet machining 

Wire-EDM 




금형의 대형화 추세 

(기존 설비 spec 초과) 

제품의 급경사화 추세 

(3축 고속가공 어려움) 

자동차 개발 기간 단축 

(금형 납기단축 요구) 

유럽의 금형기술 도입 

(5축 가공기술의 보편화) 

금형 설계 자유도 향상 

(금형 품질 개선) 

대형 

5축 가공기

설비 크기 

가공 공작물 최대 크기 

측면 가공을 위한 설비 HEAD의 동작 구간 고려 

설비 형태 및 사양 

5축 적용 대상 및 적용 범위, 공작물의 크기 및 중량 고려 

공작물과의 간섭 가능성 

CAM SW 선택 

Tool path 생성 신뢰성 및 연산 속도 

3축 tool path의 5축 변환 기능 (쉬운 5축 적용) 

Post Processor 능력 및 기술 지원 능력 

검증 SW 선택 

S/W의 신뢰성 및 기술 지원 능력, 쉬운 사용자 인터페이스 

공구 holder 선택 

홀더의 길이 및 형태, 다양한 규격의 holder 및 sleeve 

ATC 사용 환경을 고려한 홀더 수량 검토 


구분 unit DINO-1 DINO-2 

MAKER FPT(ITALY) 

TABLE SIZE(X*Y) mm 3000*1200 

STROKE(X*Y*Z) mm 2800*2200*1000 

Speed m/min 35 

Spindle RPM rpm 


10,000(3축) 

18,000(5축) 



B/C축 LIMIT Deg. B축 : ±185 C축 : -93~+273 

Load TON 10 

HOLDER TYPE HSK-A63 

HSK-A63 

HSK-E40 

ATC EA 60 30-30 

CONTROLLER HEIDENHAIN iTNC530 

3D measuring 

(M&H TOUCH PROBE) 

AHC 

(AUTO HEAD CHANGE) 

자동 교환 

OMM 

(On Machine Measurement) 

Verification

1 H/L LENS 


- UPPER C/P 

3 H/L LENS 

– OPTIC M/C 

2 H/L & R/C BEZEL 

- UNDER C/P 

4 R/C T/STOP LENS 

– UPPER C/P

Die design Part modeling Tool-path generation Work instructions 


Machining 

SOS 

PowerMill 

MCV 

Verification 

E-Worksheet 

Workpiece 

Set-up 

Tool-paths 

Tooling 

MC’ng Cond. 

Post processing

황중삭: 7 공정 (49:21) 

◦ 7, 0, 0 

중정삭: 22 공정 (23:43) 

◦ 12, 9, 1 

정잔삭: 19 공정 (9:58) 

◦ 2, 11, 6 


Tool length optimization 

◦ Continuous & positional 5-axis processes 

◦ Interference avoidance & improved machining 

condition 

Tool orientation optimization 

◦ Positional 5-axis processes 

◦ Interference avoidance & improved machining 

condition 


◦ Interference check, machine animation 



공구 길이 증가 

Tool length optimization 

Tool orientation verification & optimization 


37

Facet 

Input Model 


CAD model 

Z-map 

Hybrid model 

Z-map Model 

Hybrid Model

NC-view 


Machine 

simulation 

(Autotooling) 

SOS 

(Setup & Operating 

Supporter) 

System 

Easy 

editor 

NC 

Convertor

Design 

Accuracy 

Quality 

Delivery 


•Flexible design & structure 

•1 Set-up 

•Tool-length 

•Deep cavity, corner cut 

•Machining time 

•Reduced EDM process 

30 % of productivity increase


개발 기간 

◦ 1990.9~1991.2 

◦ 2001.1~2002.12 

개발 배경 

◦ 일본 K사에서 개발한 CAM 소프트웨어 사용으로 매년 프로펠 

러 매출액의 일정액을 로열티로 지출. 

◦ ‘90 당시 연간 150~200여대 생산, 매출액은 천억원에 달했음. 

◦ 로열티 지출 중지, 자체 소프트웨어 기술력 확보 등의 이유로 

개발 

결과 

◦ 로열티 지출 없음. 

◦ 자체 기술력 확보. 

◦ 1차 개발 후, 2001년 보완을 거쳐 2008년 현재까지 사용하고 

있음. 





공구: face mill, side mill


①Edge-F face 

(익탕도 가공) 

⑦, 

⑧ 


⑦, 

⑧ 

FACE 

Pressure 

side 

②Edge-S face 

①,⑤, 

⑥ 

③, 

④ 

② 

③익면가공 

face 

⑤Anti-singing 

Below 

⑦Above Below 

(Back) 

④Middle Path 

(Face) 

⑥Edge gauge 

⑧Below 작업방 

법

Machine Spec. 

•MBP-110 

•MBP-95 

Snout Spec. 

•L, S, V 

•Below 

•Alpha 

Cutter Spec. 

•Face mill 

•Side mill 

•Round mill 

•Extension 

Propeller Spec. 

•CW/CCW 

•Blade # 

•r/R range 


NC code List file 

CC-data 

Surface F, Fi, B, Bi 

Edge: Sr, S, F, T, AS 

Boss/Fillet 

Kinematics Interference check 

•Fwd Kinematics 

•Inverse Kinematics 

•Below machining 

Post-Processing 

•Tool-path linking 

•Tool Approach 

•Tool Retreat 

•NC formatting 

•Feed control 

•2Head, 1Head 

•Stoke-over 

•Gouge 

•Mtr/Head collision 

•RAM collision 

•Bwd C move (2 H) 

Solution Search 

•Optimal Heel/Rot 

Joint smoothing 

•Machinability chk 

•CC-interpolation 

Surface model Edge model 

NURBS surface for 

face & back 

Workpiece modeling 

•For gouge check 

•For collision check 

Fine Z-Map 

Rough Z-Map 

Tri. Facet 

Sf/Edge quality check 

•Curvature values 

•Boundary eval. 

Report 

FACE: Edge-Sr, Edge-S, Edge-F, 2Head, Below(B), Anti-S (F/B), Boss/Fillet 

BACK: Edge-S, Edge-Tip, 2Head, Below(F), Edge-C, Boss/Fillet 

TE & LE sf (NURBS) 

Edge curve (NURBS)

M/C Library 

Part.STL 

Part.STL 

Axis Stroke 

Axis Stroke 

Kinematics 

Kinematics 


M/C Inform 

Machine # = 095/110 

Snout type = L/S/V 

Snout angle 

Cutter = F/S/U 

Chucking = N/B 

Extension = 0 or 50 

Machine model 

Construction 

Prop Model 

Hb-k.nbs/Hf2-k.nbs 

Hf-k.nbs/Hb2-k.nbs 

Blade #(type) = +-4 ~ 6 

Propeller model 

Construction 

Structure Kinematics ZMAP ZMAP 

Animation Stroke chk Cutting Collision 

Sectioning 

ZM API 

Rendering 

G. Check 

ZMAP 

Log 

OpenGL 

Animation 

Ref 

NC file 

Pre-Processor 

Pass List 

(Std P, Cut PTs, Etc) 

Axis Sum Chk 

VERIFY ENGINE 

Z-Master





Sensing surface 

Grinding Cutter 

Laser Displacement Sensor

사무실 PC 

"프로펠라 모델러" 

HX165S 

Robot 


1 

HYUNDAI 

LAN or FDD 

프로펠라 모델 

위치보정용 

로봇 프로그램 

2 

로봇 제어기 

위치보정 

데이타 

제어용 PC 

"로봇운영 시스템" 

위치보정 프로그램 

생성 소프트웨어 

4 

3 

센싱용 


아날로그 

입력 

계측 프로그램 


5 

계측된 데이타 

(POSE.G00) 

Tool 

가공 프로그램 


6 

OLP system 

가공용 


레이저 변위 

Sensor

Calibration 

(CAD vs. Work-piece) 

NURBS model 



Message box 

Robot Program 

Abs. joint values (inc. values)

160 mm 

x 

T 

y 


z 

z6 

ThDist = 215 mm x6 

Y = 214.5 mm 

X = 464 mm 

Sensor 

TCP 

y6 

x 

Tool 

TCP 

y 

z6 

ThDist = 215 mm 

x6 

Y = 276 mm 

X = 387mm 

z 

y6

충돌 (collision) 

공구간섭 (gouge) 

축 값 벗어남 (stroke-over) 

사용자 설정값 벗어남: 

◦ 로봇 Arm 간섭각, Dead-zone B축값 


T 

CC 

path 


CC data (C,N) (a,b) Tool frame (CL data) 

N 

c 

p 

n 

Cutter bottom 

TC 

P p 

F 

o 

a 

F=NxT 

C, N: CC point 

T: tangent vector 

p: tangent plane 

Tf = [n o a p] 

Heel (a) : rotate Tf around F 

Rotate (b) : rotate Tf around o 

T 

CC 

path 

(a) Cutting (b) Sensing 

N 

p 

c 

o 

a 

F 

n

T 

N 


c 

p 

x 

Cutter bottom 

TC 

P p 

최적 센서 자세: heel angle = 0 

최적 공구 자세: min. heel angle 

F 

y 

z 

Rotate angle (b) 

180 

-30 0 30 

-180 

Feasible CL 

region 

Optimal (a,b) 

Heel angle (a) 

Infeasible CL 

region 

-collision, 

-stroke-over, 

-gouge


Area 1 

Area 2 

Area 3 

Process DB 

-Area division 

-Path plans 

Propeller 

NURBS 

Meas. Point (C,N) 

Feasible Sensor TCP for 

- 1 point 

- 1 path (CL smoothing) 

Robot PG Generation 

Log 

Process Planning 

Path Planning 

-Path direction 

CC Path Generation 

CC paths 

CL Pos Generation 

CL points 


Robot PG 

Robot/Tool model 

Loading 

Facet 

Kin 

Inverse Kin 

Forward Kin 

Collision Chk 

Stroke chk 

Cutter 

Motion Interp. 

Measuring Measured Points 

NURBS 

Propeller model 

Construction 

Facet 

Z-Map 

Gouge Chk 

(machining) 

CL Computer CL Optimizer 

Path Linking

Robot/Tool model 

Loading 

Facet 

Kin 

Inverse Kin 

Forward Kin 


Collision Chk 

Stroke chk 

Cutter 

Motion Interp. 

I/F check model 

Construction 

Z-Map 

Gouge Chk 

CL Computer CL Optimizer 

Path Linking 

Iso CC Cv Gen 

CC pos Mod 

Fairing Grid 

Propeller 

NURBS 

Propeller 

Model 

M. Surface 

(Tri. Facet) 

Depth of 

Cut 

Log 

Visualization 

Path Planning 

-Path direction 

-Depth of cut 

CC Path Generation 

CC paths 

CL Pos Generation 

CL points 


Robot PG 

Comparing 

MI Data 

Loading 

Area 1 

Area 2 

Area 3 

Process DB 

-Area division 

-Path plans 

Cutter Contact Point (C,N) 

Feasible Cutter TCP for 

- 1 point 

- 1 path (CL smoothing) 

Robot PG Generation 

Sensing 

data


CAD model


2,681 points 

(15 min)

Triangular facet 




Hardware 

◦ Speed (rotary axis), Accuracy & Rigidity 

◦ New kinematic structure 

Software 

◦ Optimization 

◦ Intelligent & integrated CAPP system 

Design & manufacturing process 

◦ DFM (ex: mold design) 

◦ One set-up complete machining: roughing to clean-up 

on the machine 


Why not 5-axis? 

◦ Expensive machine tools, software ? 

◦ Hard to use ? 

◦ Can’t or Don’t ? 

Quotation 

◦ …… As time passes, 5-axis machine technology will 

completely alter the landscape of manufacturing as 3axis 

machines move to the history books. 

Risk meets reward with 5-axis machining, by Glynn Fletcher, 

President of GF AgieCharmilles, American Machinist, 2008.2 


Apro 2009 

◦ Secrets of 5-axis machining, Karlo Apro, IP, 2009. 

Choi 1999 

◦ Sculptured surface machining, B. K. Choi, Kluwer, 1998 

Makhanov 2007 

◦ Advanced numerical methods to optimize cutting 

operations of five axis milling machines, S. Makhanov, 

Springer, 2007 

American Machinist 

Modern Machine Shop (MMS) online 

Journal papers

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