Staub goes 5-Axis

Our newest and most notable addition to our equipment list is a 5-Axis Manufacturing Cell. Custom-made, installed, and making chips is an extremely unique system. Now that we’ve got our 5-Axis system off the ground, we’re proud to share some of the details!

5-Axis Manufacturing Cell

• DMU60 eVo Linear 5-axis machining center
• Fanuc Robot
• PH50 Pallet Storage System (capacity for 35 pallets), Pallet Manager, and Work Setup Station
• Siemens CELOS cell controller system

What is 5-Axis Machining?

5-axis machining is used in applications that require machining of complex geometries. The main benefit is the ability to machine complex shapes in one setup, which not only reduces labor time, but also increases feature-to-feature accuracy. In addition, 5-axis machining allows machinists to use shorter tools and cut at higher speeds, which yields faster machining and more precise blending. This technology has changed the way that complex shapes are machined, and has opened the doors to more creative engineering solutions in manufacturing.

Some applications require the use of all 5 axes at the same time, like you see in the videos above. Complex shapes that require contouring will allow the machine to move the table and the spindle to create 5 axes of movement. Other applications require 3+2 machining. In 3+2 machining, the traditional 3 axes are used, but the tool can be positioned with the 4th and 5th axes to machine difficult features on the workpiece, such as angled holes and undercuts. For a comprehensive description of these machining methods, here is a detailed (and interesting) article from Engineering.com.

Applications for 5-Axis Machining

As design and manufacturing capabilities continue to grow and evolve, parts, assemblies, and systems are becoming more complex. This requires us to find economical ways to produce them. Aerospace companies are designing and installing complex pa
rts for fuel systems, defense companies are applying this technology to weapons systems, medical companies are designing new tools and implements, and injection molding companies are using 5-axis technology to create complex molds in fewer steps and setups. As engineers and machinists continue to push the envelope in design and manufacturing, applications will continue to expand.

Staub’s Take on 5-Axis Machining

Most companies who invest in a 5-axis machining center do so as a one-off, prototype, or low-volume producing piece of equipment. We took a very different approach. We asked DMG MORI to create a 5-Axis Manufacturing Cell. The star of the show is the DMU60 eVo Linear machine tool. The DMU60 gives us a 120 tool magazine, a work area of 23.6″ x 19.7″ x 19.7″, 24,000 rpm, and super fast tool changes and rapid traverses. It is complemented by a Fanuc robot that moves pallets to and from the integrated pallet rack. The rack accommodates 35 12″ square pallets. This cell will allow for continuous, unattended production in this manufacturing cell.

The system that we have installed will be of most advantage for projects that require repeat work. Higher volume jobs will allow us to take advantage of the savings provided by maintaining fixtures and tooling that are perpetually setup. What does this mean to the customer? We have virtually zero setup time to get your parts up and running. By allowing the operator access to 35 pallets without interrupting the machine, we can also ensure optimum productivity and efficiency – and pass along those cost savings to our customer.

Why Now?

Much of the 5-axis machining that is done in our industry is for low-volume applications and prototyping. In Staub’s estimation, there is a gap in demand for, and supply of, production quantities of geometrically complex machined parts. Staub has vast experience in production manufacturing, and it is this experience that will be the main factor in our success in filling this gap. It is Staub’s goal to bring the lessons learned in efficiency, attention to detail, and automation to the 5-axis market.

If you’ve got an application that might fit, or if you’d like to learn more about our system, drop us an email or give us a call!