Continuous 5 Axis Machining with TopSolid CAM

One of TopSolid'Cam's greatest forces is its capacity to manage all machining processes thereby making it one of the only CAM solutions on the market which is able to machine all parts by offering the most suitable machining process. TopSolid'Cam is capable of piloting turning, 2 axis milling, 3 axis milling, 4 & 5 axis continued milling, 4 & 5 axis continued turning, synchronization and complex simulation.

The optimization of the digital calculation of objects has led designers to create shapes which can only be made by using machines able to operate in 5 continuous axis. Before looking at what TopSolid'Cam proposes for the machining of such parts, let's take a look at the two main cases where continuous 5 axis machining is used:

• Machining of parts which cannot be made without a 5 axis machine tool. In general, 5 axis machining is required to manage accessibility constraints to certain areas of the part and means that the part cannot be made on machines with fewer axis.
• Machining of parts which can be carried out on 3 axis machines. In this case, the main reason behind using a 5 axis machine (when the part could in fact be machined on a 3 axis machine) is to allow the use of shorter tools which offer better cutting conditions and thereby reduce manufacturing times.

Spinning wheels, aeronautical parts and air ducts of certain cylinder heads are some examples of parts which can only be manufactured using a 5 axis machine tool. TopSolid'Cam offers two main strategies for the machining of such parts:

• 5 Axis Sweeping: With this machining method, the tool never works at the extremity, where the cutting speed is worst. The problem of accessibility to certain areas of the part are eliminated and therefore turnaround times are reduced.
• Swarf Machining: This machining method limits the number of machining passes by using the side of the tool instead of its extremity. Machining is therefore cleaner and faster.

For parts which may be machined on a 3 axis machine, TopSolid'Cam offers the possibility to transform a classical 3 axis tool path into a 5 axis tool path. This option permits the use of shorter tools which offers better cutting conditions, a reduction of possible vibrations and a significant reduction in machining times. This function is frequently used by mold makers, for whom the automatic management of collisions, now available in TopSolid'Cam, is very important. This means that the tool orientation is automatically modified in the case of a collision or rubbing with the part.

We have seen that TopSolid'Cam offers continuous 5 axis machining solutions to its customers which reduce machining times, increase part quality and reduce tool costs. TopSolid'Cam also offers other powerful functions which are essential for continuous 5 axis machining:

• Collision Management: TopSolid'Cam automatically modifies the orientation angles of tools in order to avoid collisions.
• Simulation: Simulation is a key issue in all machining processes, especially in continuous 5 axis machining. TopSolid'Cam manages all interoperation movements, collision prevention, axis movements, rest material, etc. Unlike many CAM solutions on the market today, TopSolid'Cam does not only simulate the tool but also the machine and the part and thereby permits good machining of the part.

TopSolid'Cam - One solution which evolves with your needs.

TopSolid'Cam manages all machining processes from 2D to 5 axis machining. One of the main interests of TopSolid'Cam is the richness of functionalities it offers to its operators. The sub-contractor who works in 2D today might need to machine complex 5 axis parts in the future in order to stay competitive. With TopSolid'Cam such a company can take on new complex parts with TopSolid'Cam without the fear of having to change software if its work processes change. TopSolid'Cam allows companies to change and develop their activities with one software solution.

TopSolid'Cam offers:

• Polyvalence for all machining operations enabling sub-contractors to carry out all machining operations they may encounter including 2D, 3D and 5D milling, turning and wire electro erosion.
• Integrated simulation which enables operators to easily manage accessibility problems during the programming of complex lathes/milling machines.
• Excellent stock management so that all machining operations take into account the correct stock model.
• Automatic machining linked to the topology of the models
• Automatic recognition of features such as holes, pockets, grooves, bosses, etc.
• ...

About Missler Software:
Missler Software is one of the leading global suppliers of CAD, CAM and ERP solutions. The company's product lines include TopSolid, TopManufacturing and GOélan. Missler Software offers a uniquely integrated solution for the mechanical engineering industry (general mechanical design, special machinery, tooling, boiler work ...) and for the sheet metal and wood industries.
Thanks to its advanced technology and its fully integrated solution, Missler Software is experiencing rapid growth in the global CAD/CAM market. For further information, email us.