Five Axis machining has been used in aerospace

applications for many years but it is only recently that

the toolmaking industry has shown similar interest. The
main advantage of 5 Axis machining is the ability to save
time by machining complex shapes in a single set-up.
Additional benefit comes from allowing the use of shorter
cutters that permit more accurate machining.
Positional 5 Axis machining has long been available
within PowerMILL. With this technique, the head is
oriented into a series of positions and machining carried
out as a set of discreet operations.
In addition to this, PowerMILL now offers continuous 5
Axis machining. Continuous 5 Axis machining allows the
user to create continuous 5 Axis toolpaths across
complex surface, solid and triangulated models. The
toolpaths are fully gouge checked and support a wide
range of machining strategies and all tool types.
Benefits of Positional 5 Axis Machining
Ideal for machining deep cores and cavities
Short cutters give increased accuracy and higher
quality surface finish
Allows the machining of undercuts
Significant time benefits through use of only one
set up
Benefits of Continuous 5 Axis Machining
Ideal for profiling parts
Ideal for machining deep cores and cavities
Short cutters give increased accuracy and higher
quality surface finish
Allows for machining with the flank or bottom of
the tool.
Can be used with a full range of tool types.
Full gouge protection
Can be used with models in STL format (with the
exception of profiling)
Features and Functions
Surface Finishing
Swarf Milling
Profiling
Trimming
Pocketing
Slotting
Multi axis Drilling
Integrated 5 Axis Post Processor
5 Axis Machining
w w w . d e l c a m . c o m
Slotting
The machining of the example shown required the
slot to run around the top surface with the walls of
the surface maintained perpendicular to the top
surface. Here the bottom of the tool is used to
machine the groove by taking multiple cuts. By using
a lead angle of 0 and with a gradual step-down of
0.5mm the groove is progressively machined to depth.
This technique is particularly useful for machining of
sealing grooves in complex surfaces and for
machining gauging lines on large checking fixtures.
Surface Finishing
PowerMILL now allows the user to create continuous
5 Axis toolpaths across multi complex surface, solid
and triangulated models. A wide range of machining
strategies can be used to machine models that would
previously require multiple set ups. PowerMILL 5 Axis
toolpaths are created by defining side angle, lead and
lean for the tool.
Swarf Milling
Swarf Machining can be used for profiling the edge of
components using the side of the tool to remove
material. By creating 5 Axis contour paths around the
surface edges of the part this technique can be used
for profiling undercuts as shown or for trimming of
vacuum formed products where the side of the cutter
is maintained perpendicular to the edge. This
technique is also ideally suited for machining pockets
in aerospace products with angled walls.
Multi Axis Drilling
Conventional 3 Axis drilling of this component
would require a different setup for every hole,
around the side and top. With PowerMILL Multi-
Axis drilling this can be completed in one set up
with the most efficient ordering of hole drilling.