Advanced Machining Center Setup

&
Development of CNC Post-Processors

Eduardo Luís Mateus Chocalheiro

Mechanical Engineering Department, Instituto Superior Técnico, Technical University of Lisbon,

Lisbon, Portugal

Abstract
Multi-Axis Machine Tools are increasingly used in the manufacture of parts, because they
allow their execution with fewer fastenings and consequent gain in overall accuracy, as well as
executing more complex geometries. Among Multi-Axis machines, those who have had greater
application and evolution at industry level are the Numerical Controlled (NC) Milling Machines.
However, the installation of these production units requires a great number of procedures at startup
level, the preparation of clamping devices, tools and, especially, the Computer Aided Design and
Machining softwares (CAD/CAM).
This master thesis is developed in the field of installation of a 5-Axis Machining Center and its
auxiliary systems for its normal functioning. This work was held at the worksohp of Instituto Superior
Técnico of Lisbon and it was developed from the reception of the equipment, through network settings
to the startup operation. It was also necessary to apply certain procedures for proper installation and
functioning of the machine, installing CAD/CAM softwares and develop Post-Processors.
This master thesis work made it possible to consolidate the installation procedures and startup
of 5-Axis Machining Centres, as well as perform a comparative evaluation between some CAM
softwares and the development of Post-Processors.

Keywords: Machining; Multi-Axis; CAD/CAM; Post-Processor.

1. Introduction

Thirty years ago, industrial companies wondered if it would be worthy to replace the
conventional machines by CNC technology. Nowadays, the 5 Axis CNC’s, are presented as valuable
alternatives to the traditional 3 Axis. In any business, investing in the latest technologies has the
repercussion being placed ahead of the rest of the market. In the other hand, companies that remain
faithful to traditional machines ended up losing competitiveness in an increasingly global market.
Keeping those things in mind, and because Instituto Superior Técnico is well known for being
one of the major engineering universities, the DMG DMU 50 Eco was the chosen 5 Axis CNC
Machining Center to integrate NOF, the renewed workshop center. It is renowned for the wide range of
geometries that can perform. However, it demands a previous study by an engineer to withdraw as

1
much as possible from the machine. With the increase of machine´s versatility, comes the increasing
number of machining planes, which triggers the project´s complexity. Thus, the use of Computer-Aided
Design (CAD) and Computer-Aided Manufacturing (CAM), or CAD/CAM software becomes essential.
Those softwares allow designing new parts, creating the required numerical control program in a short
time and making geometrical changes in real time. The CAD/CAM technology enables to save more
time, resources and production costs with efficiency and accuracy.
Once the design and machining project are done, it is required to upload a file with the
machining paths to the machine’s controller. The interface works as a translator between these two
technologies is the so called Post-Processor. There are many different controllers’ trademarks and a
vast number of CAD/CAM software’s. Therefore, specific Post-Processors need to be developed for
each controller-software set.
Once the equipment have been chosen, it is necessary to select which tools are going to be
use depending on the diversity of geometries required. The more diverse and versatile they are the
more productive capacity they have.

2. Brief Review of 5 Axis Machining

5 Axis machining is, at this time, the cutting-edge technology that many companies have
access to. Machines with this technology can not only position the tool but also in any rotated position
of the 3D coordinate system.
To understand the characteristics of a machine, it is required to understand the basic
terminology of 5 Axis machining centers. In a common 3 Axis milling machine, the linear axis that
define them are the X, Y and Z. In 5 Axis milling, there are 2 of 3 additional rotary Axis, which rotate
around the three linear Axis: A rotate around X, B around Y and C around Z.

Figure 1 – 3D Coordinate System

Whenever is possible, a 3+2 milling type should be chosen, i.e. using both rotary Axis only for
position the workpiece: it’s easier to program, the cut is faster and there are fewer risks of unexpected
collisions between parts. Moreover, it’s the most suitable mode for roughing. Even though 5 Axis
machining is impressive to watch, it is slower, harder to program and makes the machine less rigid.
It´s better to create a part with 5 sided machining instead of simultaneous 5 Axis.

2
 2.1 Machining Centers

Long before CNC machine tools were invented, metalworking was handmade on conventional
milling machines. The operator had total control over the operations and machines were purely
actuated by mechanical mechanisms.
The first NC (Numerical Control) machines appeared late in 1940´s. They were huge, heavy
and extremely difficult to operate. The instructions were given by punched paper cards containing a
sequence of G-Code to position tools. Nevertheless, NC machines were adequate for mass production
and, for this reason, throughout 1950’s they have become the industry standard. But with the
development of computers as we know, they started to upload the G-Code into machines and the
concept of Computer Controlled Machine (CNC) emerged in 1967. In 1972, another revolution
emerged with the development of first CAD/CAM software. Finally, in 1989 came out to the market the
first 3D software and CNC machines have become the industry standard.
Even if today many CNC Machinig Centers had the possibility to directly program in the
controller the tool paths required for a certain job, CAD/CAM softwares would still be the most used
tool to create new workpieces. However, each CAD/CAM-controller set requires a unique Post-
Processor to translate those two different technologies. In the past years, Post-Processors have
evolved in order to include a huge amount of G-Code list and tailored functions to optimize the
machining process, making it the most efficient and fast as possible.

3. DMG DMU 50 Eco Setup-ups

Any mechanical equipment must be select according to the workshop needs. On a CNC
Machining Center, some characteristics such as feed rate, spindle speed, the dimensions of the table
or the capacity of the tool magazine must be taken into account. Figure 1 present CNC Machinig
Center available in NOF.

3 2 3
6

7
4 5

Figure 2 – CNC Machining Center DMG 50 Eco: 1) Spindle; 2) Controller; 3) Tool magazine; 4) Chip deposit; 5)
Machine’s floor; 6) Power distribution; 7) Rotating table

3
 Beginning in the transportation, throughout technical trainning, network settings and tools
selection, all stages are important, and a right choice of the required equipment to achieve the order
specifications is a crucial issue. Selecting the right operating conditions is very important in order to
fulfill the desired quality requirements at the lowest price.
So as to make the machine more versatile, and execute the biggest number of geometries, a
tool set was chosen as wide and varied as possible to the machine´s tool magazine.

Position Tool Name  Cut

1 Center drill bits CDB_D2
Generic Operations

2 Spher Mill SM_D2 2

3 Drill D_D3 3,5
4 End Mill EM_D4 4
5 Tap M4 T_M4 4
6 Spher Mill SM_D6 6
7 Drill D_D7 7
8 End Mill EM_D8 8
9 Tap M8 T_M8 8
Empty 10 - -
11 Inserts tool TIT_D63 63
12 Inserts tool RIT_D40 40
Milling
Rough

13 Inserts tool FIT_D40 40

14 Inserts tool RIT_D16 16
15 Inserts tool FIT_D16 16
Empty 16 - -

Table 1 – DMG 50 Eco Set of Tools

4. Posts-Processors Development

Firstly it is required to explore the Sinumerik 810D functioning, the controller’s machine, in
order to understand what pre-cycles it has at disposal. These cycles reduce significantly the number of
lines required for the same job just to create a good and efficient Post-Processor that explores all the
machine´s potential.
Besides ShopMill, the integrate CAM solution in the machine´s controller, three different
CAD/CAM softwares were chosen in order to know which would be more appropriate to machine´s
controller: MasterCam, SolidCam and NXCam. Because all three softwares are very different from
each other, the time spent exploring them was the same. However, the time spent developing new
Post-Processors wasn’t.
MasterCam is one of the leading CAD/CAM software in the industry, because it is reliable and
very thorough. It was the software tested in the first place, but a dedicated Post-Processor was not
developed, because it already existed one in the school. To implement in the machine, few changes
had to be applied in the Post-Processor code.
The second tested software was SolidCam, which is an add-on to the existing SolidWorks
CAD software. Even being recent in the market, it presents lots of machining operations like

4
MasterCam, However, this software works based in solid geometries. Just like MasterCam, the
software comes with some generic Post-Processors, for educational purpose. One of them was
specific for Sinumerik 810D, but only with 3 Axis. Thus the challenge was to adapt this Post-Processor
to the NOF Machining Center. After several weeks, this solution was putted apart, once the controller
does not accept the required rotating Axis. As described, this machine only rotates B and C Axis.
Assuming we want to rotate A Axis, the Post-Processor needs to do a coodinates' change, in order to
transform this command into a relative move between B and C axis. Since this problem couldn’t be
solved, the solution was directed to another CAD/CAM software.
Finally, the last tested software was the NXCam. It is very similar to SolidCam in terms of
interface and performs as well as the others. Like the others softwares, NXCam comes with a range of
non-industrial Post Processors' libraries. However, the biggest advantage of it is to have dedicated
software to help developing Post-Processors, called Post Builder. As can be seen in Figure 2, the
command list of this Post-Processor is organized almost like a flow chart, making the creation of it
much easier.

Figure 3 – Post Builder

In every single job, it is required for the operator to set a reference point in the workpiece
relative to machine’s home position. However, when the table rotates, this relative point is lost. So as
to solve this problem, it is necessary to declare a new cycle (blue box in Figure 3). This so called
“Cycle800” is used to rotate any type of surface so that it can be machined. By calling the appropriate
NC functions, the cycle converts the active workpiece zero and tool offsets to refer on the inclined
surface, taking account of the kinematic chain on the machine.

5. Experimental Work

To validate the developed Post-Processors, some experimental work was done. Firstly, it was
manufactured an Aluminum dummy table. It is a very handy device when it is necessary to machine a
workpice until the very near its base.

5
 Secondly, a case study was projected to test all CAD/CAM softwares, as well as to compare
the way they are machined. This workpiece was fixed to the Aluminum dummy table using
cyanoacrylate.

a) b)
Figure 4 – a) Aluminium Dummy Table; b) Study Case Geometry

For being a common material in many engineering applications, very versatile and easy to
machining, the Aluminium was the chosen material to realize this case study. As such, it was taken
into account the mechanical properties of it in the definition of the machining parameters, wich are
presented in the table below.

Spindle Speed Feed rate Stepdown

Operation Tool
(rpm) (mm/min) (mm)
Facing End Mill D16 2000 1000 1
Contour End Mill D16 2500 1000 1
Box End Mill D16 1000 500 0.5
Drill BH_D7 1000 100 1
Thread drilling M_M8 100 100 2
1
Tilt Facing End Mill D16 2000 1000
(SolidCam = 0.2)
o
Drill 90 BH_D7 1000 100 1

Table 2 – Case study machining speeds

6. Results and Discussion

As all softwares are different, the comparison was based on the programing time of a same
geometry. The Table 3 contain the operation times.
As show in Table 3, the programing times differed only by a few minutes in the first three
cases. When it needs to be done the same geometry using ShopMill, the time spent is three times
more. If there is the need to rotate the machine table, the programing time of that operation increases
an order of magnitude. When the geometry entails the rotation of any angle, the user is forced to

6
indicate which is the new reference point before the rotation, which value (in degrees) of tilt and
another reference point after. This requires either the technical drawing to have more information than
usual or commits the operator to manually calculates the new reference points.

NXCam SolidCam MasterCam ShopMill

Preparing 00:55 00:35 01:35 01:05
Facing 01:30 00:55 01:05 00:35
Contour 02:00 01:05 00:55 01:10
Box 01:40 01:10 01:10 01:25
Drill 02:05 00:40 00:40 01:10
Thread Drilling 01:10 00:45 00:45 00:30
Tilt Facing 01:45 01:10 02:30 20:35
o
Drill 90 01:45 00:55 02:35 02:05
Total (mm:ss) 12:50 07:15 11:15 28:35

Table 3 – CAM Programing time of the case study

After generating, the NC files were uploaded to machine´s controller in order to execute the
same geometry with 3 different softwares. The MasterCam file was not performed because it´s Post-
Processor, as said, were not developed to DMG 50 Eco. The case study running times are showed in
Table 4.

NXCam SolidCam ShopMill

Facing 04:50 04:40 05:05
Contour 03:00 03:05 03:10
Box 02:45 02:35 04:30
Drill 00:20 00:20 00:35
Thread Drilling 00:25 00:20 00:55
Tilt Facing 02:15 06:45 03:05
o
Drill 90 00:30 ------ 01:05
Total (mm:ss) 14:05 17:45 18:25

Table 4 – Case study running times

Once the technological data for each machining operation is the same, it would be expected
very close running times. However, some values diverge 30%. These differences are due to the path
and speed at which the tool approaches the workpiece (rapid moves in G00). Both NXCam and
SolidCam allow users to refine these strategies, while in ShopMill you can only set the cutting moves.
For this reason, NXCam is up to four minutes faster than ShopMill when performing the same
operations. As mentioned above, SolidCam Post-Processor´s is only working with three linear Axis.
Therefore, it wasn’t possible to run the 90 degrees hole and the rotated facing had to be done with a
different technique, using a contour around the slope with a small stepdown. These facts resulted in
longer operational times.

7
 But more relevant than time spent in the machining process, is to assess whether final work is
according to project and design requirements. Figures 4, 5 and 6 illustrate the final result in NXCam,
SolidCam and ShopMill, respectively.

a) b)
Figure 5 – NXCam Geometry: a) Overall Vision; b) Detail

a) b)
Figure 6 – SolidCam Geometry: a) Overall Vision; b) Detail

a) b)
Figure 7 – SolidCam Geometry: a) Overall Vision; b) Detail

As figure 4 to 6 illustrate, the surface finish of all the pieces is quite similar because
technological parameters where the same, regarding on some aspects. The only part with the same
geometry and dimensional accuracy of the case study is the one done by NXCam. Despite having

8
good surface finish, the piece executed by SolidCam does not fulfill the project requirements, because
it was done by a 3 Axis Post-Processor. Therefore, the 90 degrees drill couldn’t be done and the tilted
facing has a ladder format. Finally, the workpiece performed in ShopMill: apart from the tilted milling,
all operations have the dimensions and geometry required by project. As mentioned, it’s extremely
difficult and time consuming to compute new reference points and rotation angles whenever there is
the need to rotate machine´s table and satisfy geometrical needs. In this case study calculation of new
rotation angles resulted as expected. However, the geometry didn´t, with visible defects showed in
Figure 6 b). This was due of a deviated calculation of the reference points, both before and after
rotation.

7. Conclusions

Every step in the process of implementing a CNC Machining Center on a workshop is crucial.
But the challenging part is the development of a Post-Processor. It forces you to deeply know the
CAD/CAM software and its programing routines, as well as the machine.
The easiest Post-Processor to develop, and the one which takes advantage of machine’s
potential, was the NXCam’s. Having its own software to develop new Post-Processors, with an object-
oriented programing style, makes it simple to create new ones. And because NXCam belongs to the
same company of the machine´s controller (Siemens), this software already has been prepared for
similar programing routines.
From the three tested CAD/CAM softwares, the choosing criteria lies not in the required time
for programing the machining tool paths. Especially in a workshop like NOF, where programing and
execution times are not as important as the final quality of produced products. Regarding the
geometrical accuracy of the parts done in the machining center, it turns out that for simple geometries,
requiring only three Axis, NXCam, SolidCam and ShopMill are much alike. However, when more
complicated projects needs to be done, results are different. For more complex geometries, ShopMill
won’t perform as well as the others, since the programing difficulty increases with the increasing
number of Axis required to perform the operation.
As expected, for more complex geometries, requiring the rotating Axis, the recourse to
CAD/CAM software is essential. Not only allows more flexibility in the machining tool paths
programing, but also has a secondary function such as simulation of the different stages of
manufacture and collisions verification between the tools and the workpiece. To NOF, the ideal choice
is NXCam, which was the one that exhibited the best response to the referred needs.

9
References

[1] Mesquita R. M. D., Rodrigues J. M. C. and Baptista R. M. S., Notes of “Machine-Tools” Part I,
Instituto Superior Técnico, Technical University of Lisbon, Portugal, 1997.
[2] Rodrigues J., Machining Notes – Milling, Instituto Superior Técnico, Technical University of
Lisbon, Portugal, 2009.
[3] Karlo A., Secrets of 5-Axis Machining, Industrial Press Inc., 2008.
[4] Simões, J. F. C. P. A., “3 and 5 axis Milling Technology on Sculptured Surfaces”, Master
Thesis on Mechanical Engineering, Instituto Superior Técnico, Technical University of Lisbon,
Portugal Lisbon, Abril de 1997.
rd
[5] “Easy Milling with ShopMill”, 3 Edition, Siemens, 2004.
[6] “Sinumerik 840D/810D – Operation Guide”, 11/2002 Edition, Siemens.
[7] “Sinumerik 840D/810D – Milling and turning manual for beguiners”, 10.03 Edition, Siemens.
[8] “Sinumerik 840D/810D – Cycles”, 04.2000 Edition, Siemens.
[9] “Sinumerik Operate – Easy milling with ShopMill”, Siemens.
[10] “Sinumerik 840D/810D – Configuring the OP 030 Operator Interface”, 09.2001 Edition,
Siemens.
[11] “Sinumerik 840D – Special Functions”, 09/2011 Edition, Siemens.
[12] “Sinumerik 840D/810D – List of System Variables”, 11/2006 Edition, Siemens.
[13] “Sinumerik 840D/810D – Programing Guide ISSO Milling”, 04.2007 Edition, Siemens.
[14] “Sinumerik 840D/810D – Job Planing”, 11/2006, Siemens.
[15] “Milling with Sinumerik – 5-Axis machining, 05/2009 Edition, Siemens.
[16] “Sinumerik – Tool and Mold Making”, 08/2007 Edition, Siemens.
[17] “Sinumerik – G code Programing”, 03/2009 Edition, Siemens.
[18] “Rotating tools”, 2012 Catalogue, Sandvick Coromant.
[19] http://www.fiveaxismachining.com/index.php/why-5-axis/ [2012].
[20] http://www.mundocnc.com.br/avan11.php [2012].
[21] http://www.dormertools.com/sandvik/2531/Internet/French/s004449.nsf/Alldocs/Product*2DMa
chiningSolutions*2DPDF*2ATH*2DPDFpt/$file/8Fresamento.pdf [2012].
[22] http://www.moldmakingtechnology.com/articles/how-to-choose-the-right-toolholder [2012].
[23] Tony L. Schmitz, Kevin Powell, Dongki Won, G. Scott Duncan, W. Gregory Sawyer, John C.
Ziegert, “ Shrink fit tool holder connection stiffness/damping modeling for frequency response
prediction in milling”, International Journal of Machine Tools and Manufacture, July 2007.
[24] http://numeryx.com/cnc/5axes.htm [2012].
[25] http://www.robots.com/articles/viewing/cnc-milling-machine-evolution/1554 [2012].
[26] http://www.cometproject.eu/publications/gizelis-robots-replace-cnc-machines.pdf [2012].
[27] http://www.sescoi.com/multi-media/cam-software-articles/cncprogramming/#c40310 [2012].
[28] http://www.sandvik.coromant.com/pt/knowledge/materials/cutting_tool_materials/introduction/p
ages/default.aspx [2012].
[29] http://pt.scribd.com/doc/62622549/8/USINAGEM-DE-LIGAS-DE-ALUMINIO [2012].
[30] http://www.exechonworld.com/document/200804/article22.htm [2012].

10