Mastercam Multiaxis Flank Machining

Mastercam Multiaxis Flank is a toolpath in which machining is performed with the flank of the tool, keeping the tool’s side surface in continuous contact with the selected wall. This method is especially useful when producing accurate, smooth, and uniform walls, such as in mold cavities, turbomachinery blades, aerospace and automotive components, and other applications where the surface geometry requires 5-axis control.

The advantage of this method is efficient material removal and excellent surface quality, since machining is performed with the flank of the tool rather than only with its tip. This provides a larger contact area and more even distribution of cutting forces.

Features

• Flank wall machining: The tool remains in continuous contact with the wall surface, producing an exceptionally smooth and accurate wall.
• Stock models and remaining material: Stock and remaining material can be taken into account, reducing unnecessary movements and preventing air cutting.
• Machining patterns: The wall can be followed in one direction or with a zigzag motion. This provides flexibility for handling different part geometries.
• Compensation options: Tool compensation can be performed in the computer, in the control, using tool wear, or using reverse wear compensation. This makes it possible to use different compensation methods depending on the machining strategy.
• Tool axis control:
  • 4- or 5-axis output.
  • Ability to set fan control, angular increments, and minimum/maximum angular limits.
  • The number of tool movements can be minimized.
• Limits and collision checking: The user can define X, Y, and Z limits and use collision checking with compensation and edge surfaces.
• Bottom hooking prevention and an oscillating toolpath are also available, distributing the cutting length evenly across the tool.
• Transitions and safe zones:
  • Entry and exit curves can be precisely defined by length, thickness, height, and accumulation angle.
  • Safety and retract levels can be adjusted.
  • The safe zone can be shaped as rectangular, cylindrical, spherical, or wrapped.
• Roughing and finishing: Depth cuts, the number of roughing passes, and finishing passes can be defined. Chip-thickness control and profile-based or depth-based ordering are supported.
• Filtering and advanced settings: Toolpaths can be filtered and optimized to reduce NC code length and improve surface quality.

Applications

• Complex 5-axis parts with steep or curved walls.
• Aerospace and automotive components requiring smooth and accurate walls.
• Wall surfaces of molds and castings.
• Turbine blades and similar aerodynamic shapes.
• Machine components where wall height and accuracy are critical.

Benefits

• Consistent surface quality: Flank machining produces a notably smooth and uniform wall.
• Improved tool life: Machining forces are distributed over a larger surface area, slowing tool wear.
• Efficiency: Higher material removal rates compared with strategies that machine with the tool tip.
• Flexibility: The ability to choose different machining strategies, compensation types, and safe zones.
• Safety: Collision checking, limit settings, and safe-zone control help ensure safe machining.
• Quality control: Automatic consideration of stock and remaining material reduces errors and unnecessary movements.

Tips

• Use a suitable tool, such as a tapered or ball-nose tool, to keep the contact area under control.
• Use an oscillating toolpath when you want to distribute wear evenly across the cutting length of the tool. This is especially useful when machining composites and hard materials.
• Define safe zones carefully, especially for parts with complex protrusions and fixtures.
• To improve surface quality, try removing the filter and using the newer ModuleWorks SWARF calculation technology.
• Use zigzag machining to speed up material removal, and one-way machining to achieve the best surface quality.
• Take advantage of collision-checking boundary surfaces and compensation surfaces to prevent errors in confined geometries.

Summary

The Mastercam Multiaxis Flank operation is a powerful and flexible solution for machining complex walls. It enables the production of accurate, smooth walls by keeping the side of the tool in continuous contact with the surface. Its extensive settings, including compensation types, wall-following methods, safe zones, and collision checking, give programmers complete control over optimizing the process. Flank machining combines efficiency, surface quality, and extended tool life, making it an especially valuable strategy for the demanding requirements of the aerospace, automotive, and mold-making industries.