Axis Limit Problems
I am machining a part in my 5-axis CNC. The part is large, but its sizes are not exceeding the machine tables. However, while performing 3-axis operations, the machine gives error message since the machine axis limits are exceeded. I can machine this part in another C-axis position. However, I don’t want to find and arrange this C-axis position manually all the time for every part. How can it  be done automatically?

Solution: The cause of the problem is the insufficiency of your post processor. The standard postprocessors do not use the travel limits of the machine axes even it is entered to the post processor. Therefore such kind of axis travel limit problems can not be solved by standard post processors. As you said, one solution is to manually adjust the C-axis position to prevent travel limit exceeds. However, this is a trial and error method, that takes time to adjust and you need to do it for each part. Another solution to overcome this problem is to slide the work part from the table center. However, this method can cause severe other problems like collision of the work part with the machine walls during table rotation. Moreover, sliding can cause other axis limit problems in other operations.

MANUSpost users do not encounter such kind of problems. By special algorithm developed in MANUSpost, “3-axis automatic C-axis positioning algorithm”,  the machine automatically adjusts the C-Axis postiton to prevent axis limit occurrence. During this process, MANUSpost scan the whole code in operation, determine all the points and recognize the ones that are out of axis machine limits. Then adjust the position of the C-Axis such that all the points will be in machine travel zone. No need to manually adjust the C-axis, or no need to slide the work part.

Is it also possible to solve axis limit problems for parts that have sizes too big to machine by using “3-axis automatic C-axis positioning algorithm”?

Solution: MANUSpost first tries to solve the axis limit problem by using “3-axis automatic C-axis positioning algorithm”. If it is not possible to let in all the points inside the machine travel limits, then MANUSpost gives an error message and warns the user about axis limit exceed. This warning is really very beneficial, since the problem is recognized automatically before starting the real machining process. This saves a lot of time. Moreover, MANUSpost has an additional optional feature called “Axis-locking algorithm” and this algorithm is used to solve this problem. The user activates this algorithm on CAM program, and the machining is done by locking an axis (for instance y-axis, x-axis or diagonal of x and y can be adjusted in MANUSpost considering customer requests and machine axis travel lengths.) This algorithm enlarges the machining zone significantly, and even parts exceeding table size can be machined with this optional feature.

Do you have also solutions for axis limit problems in 3+2 axis indexed (at fixed angle) operations?

Solution: Yes, we have. MANUSpost also brings solution to axis limit problem in 3+2 axis indexed operations. MANUSpost recognizes the axis limit exceeds and if machine kinematics allows to perform the operation in alternative opposite rotation axis side, MANUSpost automatically switches the cutting tool to the alternative side and performs the milling operation. This allows the machine rotation axis limits to be used in full capacity. For instance, consider a CNC machine tool that has B+30° and B-110° rotation limits.
The plus side will be used for alternative cuts, if axis limit occurs.