"CAD/CAM," and Why It's Required to Use 5-Axis Machining Centers. Key Points for Adoption and How to Choose

What CAD/CAM Should You Consider Implementing With Your 5-Axis Machining Center?

CAD/CAM software combines functions for design and drafting (CAD) and for creating machining data for NC machine tools (CAM). It is capable of handling the entire process from designing products and molds for manufacturing to creating machining programs (NC data). It can also be used to program and machine based on customer-supplied data.

CAD/CAM software is an important factor for 5-axis machining centers, which are particularly effective for complex machining, manpower reduction, and automation.

- What size and type of businesses and industries use 5-axis machining centers and CAD/CAM?

Kimura: Our business users vary in size and span a wide range of industries, including aircraft, automotive, medical, and semiconductors. We specialize in sales and support of software for 5-axis. As 5-axis machining centers become more widespread, the scale and types of businesses adopting our software may be expanding as well.

- Of those, what percentage of companies use 5-axis machining centers together with CAD/CAM?

Kimura: I believe the rate is quite high compared to 3-axis machining centers.

- Would it be difficult to use a 5-axis machining center without CAD/CAM?

Miyake: Yes, I think it would be if you're trying to "take full advantage of the benefits of a 5-axis machining center." For simple shapes, it's possible to use the machining center's "interactive system" or manually create NC data. But with more axes involved, 5-axis machining centers require interference checks in the machining center and more efficient programming.

Aren't All CAD/CAMs the Same?

When considering adopting a CAD/CAM system, some may view it as just another piece of software, so the choice doesn't matter. However, Mr. Kimura says that this is far from the truth. Careful consideration is essential.

- Please tell us why a CAD/CAM should be chosen carefully.

Kimura: Each CAD/CAM system has its own unique features. They should be considered carefully when it comes to 5-axis machining centers. While it may be cost-effective to add 5-axis functionality to the software you already have, it's meaningless if you can't use it effectively. You won't be able to take full advantage of the benefits of your 5-axis machining center.

- So even with similar CAD/CAM, the potential of a machine tool can vary greatly depending on the choice of software?

Miyake: Yes, I think the CAD/CAM system you use is important in programming a 5-axis machining center. I also think support from the provider is essential.

Kimura: That's our company's greatest feature. After all, our software is built for machining centers.

- Have you seen cases where implementing CAD/CAM suited for a company's 5-axis machining center produced significant results?

Miyake: We often hear from users that their "defective product rates have decreased," or that "processes which used to take a long time now run smoothly." Some say the combination of a 5-axis machining center and a CAD/CAM system has "enabled them to perform high-value-added work."

- So it not only improves operational efficiency, but can also enhance company value?

Kimura: We certainly see the benefits of initial capital investment leading to companies adding more machining centers and software. We receive many applications from young people for our training services. It may not be the same as corporate value, but we hope to provide a sense of fulfillment wherever we can.

Common Concerns Companies Face When Implementing CAD/CAM and How to Address Them

Implementing a 5-axis machining center together with CAD/CAM software offers significant benefits. However, the reality is that many companies are hesitant to implement them for various reasons. We spoke with Ai Solutions about common concerns and challenges when considering CAD/CAM implementation and how to address them.

- What are the most common concerns of companies considering CAD/CAM implementation?

Kimura: Ultimately, it's the implementation cost. Implementing CAD/CAM with a 5-axis configuration involves a certain level of investment. As a result, there are often concerns about the launch period and securing the necessary personnel after implementation.

- How can these concerns be addressed to alleviate misgivings and challenges?

Kimura: First, I think it's essential to clearly define your objectives and consider which system best suits your company. As a software solutions provider, we routinely offer demonstrations and conduct various benchmarks. We also actively provide practical hands-on experience. I think it's important that companies fully understand and have a clear picture of what the post-implementation launching will look like before implementing the system.

Finding the Right CAD/CAM for Your Company's 5-Axis Machining Center

CAD/CAM systems vary significantly depending on the software, with differences in machining types, as well as in functionality and operational procedures. According to Ai Solutions, there are some key considerations when choosing a CAD/CAM system.

- What should companies look out for when choosing a CAD/CAM system for a 5-axis machining center?

Miyake: From an engineer's perspective, I'd say it's "simplicity and ease of operation." I think this is especially critical for complex programming tasks such as simultaneous 5-axis machining. We recommend hyperMILL because even beginners can learn it quickly.

Another key consideration is the "smooth movement" required by simultaneous 5-axis machining. Here, hyperMILL also offers a major advantage, as it automatically outputs smooth movements without any complicated setup.

Kimura: Furthermore, "safety" is also important. As a software solutions provider, we must absolutely avoid causing damage to our clients' machining centers.

- Why is a high level of safety so important?

Miyake: 5-axis machining centers have a large number of axes, and depending on the axis configuration, there's a risk of interference between simultaneous machine parts. Workpiece placement is also important. This is because 5-axis CAM programming isn't just about being able to generate tool movement. Debugging the program before actual machining is crucially important.

Kimura: Naturally, the mental burden on both CAD/CAM and machine operators is also a consideration. It's important to consider whether simulations can be performed in advance and whether the simulation results are reliable.
Of course, reducing debugging time on the machine is also important.

- How can companies check the "safety" of CAD/CAM systems?

Miyake: We recommend paying close attention to the simulation functions built into the CAD/CAM software. It depends on the software, but I think simulations of the tool and jig only are insufficient for 5-axis support. "Machine simulation" is essential.

hyperMILL has long offered well-established simulation functions, and we've recently released VIRTUALMachine, a completely new POST/simulation system.
While simulations based on cutter location (CL) data were previously common, this simulation system uses the NC database. CL-based simulations use the interim data before the NC data is generated. Because VIRTUALMachine simulation uses the NC database, it faithfully reproduces the actual movement of the machine. This also optimizes the movement of the 5-axis machining center.

Kimura: As the name suggests, VIRTUALMachine enables users to "virtually" integrate their equipment into hyperMILL.

- What kind of benefits can companies expect from using your hyperMILL with Brother's 5-axis machining center, SPEEDIO?

Miyake: We believe it will enable companies to fully leverage SPEEDIO's high performance. Not only does it boost efficiency with single-chucking operations, but it also makes greater use of 5-axis machining. Many may think a 5-axis machining center is unnecessary for certain geometries, but it can shorten the tool length and improve machining conditions and efficiency. We hope companies will explore the advantages of simultaneous 5-axis machines with hyperMILL.

Furthermore, we encourage companies to keep an eye on new developments in 5-axis machining. Barrel tools can significantly improve machining efficiency and reduce machining time.

"What Are Barrel Tools, and How Do They Further Enhance 5-Axis Machining Center Performance? Implementation Criteria and Effectiveness"

Implementing CAD/CAM To Maximize the Performance of Your 5-Axis Machining Center

Today, a wide range of CAD/CAM products are available on the market, each offering different functionalities, supported machining types, safety features, and operability. To fully enjoy the benefits of implementing a 5-axis machining center, it's important to implement the right CAD/CAM system for your company.

hyperMILL—the CAD/CAM software by Ai Solutions, Brother's partner company—is compatible with the hyperMILL VIRTUAL Machining Center, a simulation function joint developed with Brother. This system is equipped with features designed to maximize SPEEDIO's high productivity.

hyperMILL is currently being enhanced with automation functions for generating NC data and other features aimed at further reducing the need for manual tasks. Looking ahead, we can expect it to continue evolving into an even more user-friendly CAD/CAM solution.

For companies considering the implementation of 5-axis machining centers and CAD/CAM systems, we urge you to explore SPEEDIO and hyperMILL for your needs.