This improves surface finish and tool life. Other benefits include elimination of blend lines and the ability to continuously maintain proper cutting tool-to-surface orientation. Plus, the machines are becoming smaller and more rigid. Five-axis machines also typically provide faster axis travel and spindle speed. The value of continuous five-axis machining is evident in the shop’s ability to use just one machine for three-axis high speed machining, positional five-axis, continuous five-axis, five-axis drilling and more. For example, standard workholding devices generally do not enable clear access to multiple sides of the workpiece, whereas specialized five-axis fixtures, chucking mechanisms, and magnetic workholding are designed for that purpose. “We’re picking up work that we had to turn away,” he says.ĥ Hard Lessons from a 28-Year-Old Startup Machine Shop OwnerĪnother part of the learning curve for new five-axis users is often adjusting fixturing and workholding strategies. “It was a learning curve on the machining, but we had in-depth training through Delcam, and within days we were confident that we could replicate what we were doing in training in the real world,” Mr.

Also, full-process computer simulation helps prevent mistakes on the shop floor. “It basically comes off the machine as a finished product,” says programmer Andrew Gruening.Īlthough the shop faced a learning curve when it first implemented five-axis machining, Delcam software enables experienced users to set up templates for less-experienced operators to save time and reduce errors on future programs. Now, it uses a DMC 125 U duoBlock five-axis machine from DMG/Mori Seiki (Hoffman Estates, Illinois) and five-axis PowerMill capability from Delcam (Windsor, Ontario) to achieve more in a single setup. Before switching to five-axis technology, any given part might have required 10 to 15 setups on a conventional three-axis machine. It specializes in the design and build of injection molds for automotive, industrial and consumer industries. Superior Tool and Mold’s experience is a useful review of how five-axis machining can improve part quality and reduce lead time and setup errors, all of which ultimately lead to greater profitability.Įstablished in 1993, Superior Tool and Mold operates from a 15,000-square-foot facility in Ontario, Canada. According to the company, both the machine it purchased from DMG/Mori Seiki and the CAD/CAM software it purchased from Delcam are essential for reducing machining time and improving surface finish. Like a number of shops across North America, Superior Tool and Mold recently added five-axis capability to increase competitiveness.

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