Re: 5-Axis help

Hello Isaiah,

I am slowly working on a 5 axis CNC mill conversion of a 3 axis
GEM500 machine. This has been a huge learning experience, especially
related to HOW TO DO so many different things to build parts to make
the machine. The biggest problem so far is settling on a design that
I can build with the equipment and skills I have. The stacked
trunnion design is set aside in favor of a 45 degree wrist design for
several reasons. There are fewer parts to be welded, fewer bearings
to induce slop, more portable to different machines, and I believe it
will be stiffer. Try to complete a design and evaluate it as
thoroughly as possible for what you want to use it for. Ask for
other opinions, view other machines if possible.

As a simplified list, here is my setup;
Mach1 CNC control running on a PC (up to 6 axis)
Using 5 Gecko 201 stepper drivers and a homebuilt power supply
Software to generate G-code is still to be determined. BobCAD v18
does have a 5 axis output capability, but is sort of clumsy to use at
this point, but the $ is far less than SurfCAM or MasterCAM. I have
tried SurfCAM, and found there is a big learning curve for machining
with 5 axis. Not just in the software itself, but in the machining
processes available (swarf cutting, lead/lag angle, ...). As others
here have said, 5 axis contouring software is $$$$, so until a more
usable, cheaper package comes out, I'll probably be using my setup
(when it is finished) with G-code in 3 axis, and use 4th and 5th as
positioning for the 3 axis code.
Having rotary axis added to an existing machine usually subtracts
from the working envelope, so keep in mind any future additions/uses
when in the design phase of your machine.
My goal for this machine is to cut aluminum in decorative forms. If
it is stiff enough is still to be seen - hope so!!
Like others here said, define the uses of the machine, design,
evaluate, redesign, re-evaluate, build, test, re-evaulate, and so
on ... As a personal builder of these kinds of complex machines, you
will have lots of learning experiences (mistakes, flaws) to get
through, but in the end, the process of building is so interesting
and educational that you will be happy to have tried, even if it
doesn't come out the way you wanted the first time.
Allan

> Isaiah Bellais