Note: This article originally appeared as a Case Study From: 5/1/2016 Modern Machine Shop, Edited by Emily Probst , Associate Editor
VIDEO NOTE: Scroll to the bottom of the page for a behind-the-scenes look at 5th Axis, and hear Chris Taylor talk about how Hypermill software has helped his company.
From day one, 5th Axis Inc.’s business strategy has been to take advantage of the most advanced software, equipment and technologies available so it could competitively enter demanding niche markets like aerospace, medical and other challenging high-tech industries.
However, during the company’s entry into five-axis machining, co-founders Steve Grangetto and Chris Taylor realized their CAM software had major shortcomings—machining collisions were common, and they weren’t able to realize the full potential of their machine tools. Using Hypermill from Open Mind Technologies AG of Wessling, Germany, the company achieves faster run times, better surface finishes and overall better quality
Business grew dramatically during the company’s first three years. To meet the growing demand for complex, five-axis machining, 5th Axis purchased a new high-performance five-axis machine to accompany its original Haas machine. However, during programming, the company realized the shortcomings of its existing, mainstream CAM software. Along with unexpected machining collisions, the company couldn’t fully utilize the speed, capabilities and potential of its new high-end machine. That’s when Mr. Grangetto and Mr. Taylor decided to give Hypermill a try.
For instance, five-axis machining greatly improves part precision by eliminating alignment errors that are introduced in standard machining when a part is removed and refixtured in another orientation. It is also extremely time-efficient, because most or all of the work is performed in a single setup with no delays while waiting for an operator to unload, reload and reposition the part.
Stepping through the tool path to watch it remove material and verify that it clears the machine without any collisions is a valuable time-saver. “I do not have to walk out to the shop floor and manually look inside a machine with coolant flowing to check clearances,” he says.
By controlling the amount of volume or the angle of the cutter’s engagement, the cutter can loop into a corner. The Maxx Machining roughing module extends tool life, and machining time is reduced by 30 to 75 percent by maintaining a constant chip load, Mr. Levine says. 5th Axis can use Hypermill Maxx Machining on materials ranging from aluminum to hard materials like Inconel because its high-speed machines are fast enough to keep up with the rapid toolpath motion that is generated. “The bottom line is that using Hypermill Maxx Machining results in super-efficient and fast tool paths,” Mr. Norton says.
Open Mind uses internal experts to develop postprocessors, which it considers to be a core technology of the company. The customized postprocessors have configurable parameters that enable users to control their particular environments. This means that the core mathematics and the basic structure of the post are created and locked down by Open Mind, but 5th Axis can change certain parameters, which influence the locked portion.
According to Mr. Levine, “Some companies give the customer a tool kit and the ability to build their own post, but those guys are not there to write postprocessors; they are there to cut metal. Also, writing the entire postprocessor is too much for the original equipment manufacturer that has to ensure compatibility with various CAM software products. An alternative approach is to give the customer no control, but then they would have to call back to the service supplier to make custom changes. Our combination of locked and open is not entirely common, and we believe it gives customers the best of both worlds.”
The high-quality tool paths, advanced CAM software capabilities, postprocessor support and skilled technical support give 5th Axis the confidence to take on ever more challenging jobs that require programming complex parts, Mr. Taylor says. “With Open Mind’s help, we never burn money getting stuck on a job. Their contribution has been a really big part of the growth of our business.”
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