Technology Targets Crashes: 5-Axis Machining

As CNC machining gets more complicated, the chance of programmer and operator errors increases. These errors can cause collisions involving machine components and workpieces during the cutting process, resulting in downtime and part, tool and machine damage.

Costly crashes aren’t inevitable, however, thanks to technologies aimed at preventing collisions and minimizing their impact.

Okuma claims to be the first machine tool builder to deploy online collision-prevention technology. Developed for CNC machines running in either automatic or manual mode, Okuma’s Collision Avoidance System (CAS) integrates a 3D model of the machine, blanks and tooling with the control unit to create a virtual machine. By running this virtual machine seconds ahead of the actual one, Okuma claims CAS can spot potential problems and stop the machine before a costly collision.

Shown on the control screen of a 5-axis machining center, Okuma’s Collision Avoidance System monitors the entire machining envelope to prevent collisions. Image courtesy Okuma America.

How reliable is CAS? “As long as you’ve modeled everything correctly, CAS will operate correctly,” said Brad Klippstein, controls product specialist at Okuma America Corp., Charlotte, N.C.

In addition to a model of the machine itself, which Okuma provides, CAS requires models of the raw workpiece material, workholders, cutting tools and machine accessories. In some cases, Klippstein said, downloadable 3D drawings of the additional machining components are available online for free and CAS users simply import them into their systems.

According to Klippstein, CAS is most suitable for long and unchanging production runs “because you just have to set it up one time for thousands of parts. But in an environment where you’re always setting up different jobs and changing tooling and fixtures, some people don’t use it because it requires a bit of a time commitment to set it up every time.”