Shenzhen Alu Rapid Prototype Precision Co., Ltd.

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Step-by-Step Job Setup for Machining

1.Secure the Workpiece and Fixturing

Mount the workpiece on the rotary table or trunnion using a zero-point clamping system, hydraulic vise, or custom fixture. Ensure it's centered on the machine's center of rotation (COR) for balanced access to all five sides. For complex parts, use soft jaws or modular fixtures to minimize overhang. Torque all clamps evenly to prevent vibration.

Tip: If flipping the part for multi-sided machining, design fixtures that allow repeatable positioning.

2.Load and Prepare Cutting Tools

Measure tool lengths, diameters, and runout using a tool presetter. Load tools and holders into the Automatic Tool Changer (ATC) magazine. Verify spindle orientation and balance to avoid collisions during rotary moves.

3.Set Work Coordinate System (WCS) Offsets

This is critical for 5-axis accuracy to account for rotations. Choose a method based on your setup:  

Method 1: COR as Origin (Best for repeatable production): Probe the COR on the machine, set it as the WCS origin in CAM, and position the virtual part to match. Use a single offset (e.g., G54) for the whole job.  

Method 2: Multiple Offsets per Orientation (For 3+2 machining): Probe and define a new offset (e.g., G55 for tilted position) for each rotary angle. Ideal for quick, low-volume jobs but increases setup time.  

Method 3: Single Offset with TCPC/DWO (Most flexible): Probe one point on the part, then enable TCPC (e.g., G43.4 on Fanuc) to let the controller auto-compensate for tilts/rotations. Requires advanced options but simplifies probing.

Tip: Always probe after fixturing—use an edge finder or touch probe for X/Y/Z, then indicator for A/C axes.

4.Calibrate the Machine and Probe

Home all axes (X, Y, Z, A, C). Run a calibration routine with an automatic probe to verify squareness, backlash, and axis alignment. Check for thermal expansion by running a warm-up cycle. Adjust any offsets based on probe data.

5.Verify Program and Simulate

Import your G-code (post-processed for 5-axis). Dry-run the program at slow speeds to check for collisions, overtravel, or gouging. Use CAM simulation to visualize toolpaths, including holder collisions. Confirm feedrates (use G94 inches/min with TCPC for smoother motion).

6.Test Run and Monitor

Start with air cuts (no tool contact), then light cuts on scrap. Monitor coolant flow, chip evacuation, and vibration. Use the machine's built-in diagnostics for errors. For full 5-axis, enable simultaneous motion and watch for singularities (points where axes align awkwardly).