So I surface ground my block square, Even if you get your block machined on a 5 Axis mill id still verify that its actually square, not all 5 axis machines are that accurate,
Also you need to verify the squareness to the machines travels one its installed, I have mine dialed to within 2 microns.
The hard part is setting the WCS accurately, I originally didn't have the Lang Gauging pallet so I machined some features then rotated the vice arounds the 4 different orientations and recorded the coords, then used a circle calculation on the Heidenhain control to find the true center for the flat plate. the angle plate is a bit trickier, finding X/Y is fairly straightforward, Z is a moving target due to my machines thermal growth. I have found an acceptable solution is to freshly calibrate my probe and tool setter, then set the Z for the angle block WCS, Then I have to use the tool probe to probe each tool after I call it up to update the length as the temperature changes during the day.
The machine has Z thermal comp but it doesn't work very well and we cant temperature control our 3000sqM workshop.
TLDR, Setting the WCS and plate alignment is critical to it working well
Also Id never use 5th axis stuff, just seems too flimsy, too much is made from aluminium, Lang stuff is super nice and incredibly accurate.
I'm not dissing 5th axis "stuff",
But I have to say that is one of the very tempting things about a Makino [3 axis , boxed way ultra precise machine.] V33
i and similar is that the whole build geometry and thermal control is within a few microns. like less than 5 micron (not 5 tenths) + really good thermal growth Z control with pretty incredible spindles (for what they are designed to do.). [Insulated thick castings so thermal changes in a shop are mitigated to a large degree + scales (of course)].
The machine can make/ cut measured larger circular interpolated features to 1 micron to 1.5 micron. The table geometry (flatness) is within a couple of micron, sub micron straightness of travels, steep walls cut - flat - to sub 3 micron... and on and on,
The machine is practically a CMM and optioned out a certain way - not just having jig boring accuracies , you can actually perform various (wet) grinding operations + jig grinding cycles. [+ switchable option for machining graphite for sinker EDM applications.].
So with inspection level angle plates and other precision (static and dynamic) fixtures like air spindle rotary bearings etc. there's a lot of high quality work that can done with one super accurate 3 axis machine. [more hands on in "mind-set".]. ~ but
slower work.
For smaller mold cores seems Makino are keen to push the 5 axis - D-200 Z (5 axis accurate machine) - for parts in a pretty wide range of materials - work volume pretty much the size of a medium to large size (taller) coffee can. But the base price for a D-200 Z is about $370K
Whereas something like V33i (3 axis machine) (new) starts around $270K. Makino do make a +/- 1 arc second-ish small 5 axis trunnion unit / rotary but that does take up a lot of good real-estate (table wise) on a V33
i or even V56
i
The Makino F3 and F5 are more of a compromise being built in Singapore (all good) but with linear rolling element slides rather than box ways of extreme precision. $175 to $250 K proposition but probably more 'Aluminum" / Aluminium friendly.
_____________________________________
V33
i and V56
i It's like a reference surface + cmm + jig grinding, jig boring and mold capable mill in one + very accurate mechanical and optical mold making "machine". + very stable over long periods of time + SGI ("Super Geometric Intelligence" - at least great / sensible / smart / clean surfaces and contours.).
I know that's a little "Off topic" vis a vis precision rotatable / indexable and referenceable clamping and fixture systems + thermal management / z control + Mold core issues.
Time spent correcting 5 axis machine work on three or four other machines vs. multiple set ups on orthogonally ultra precise and stable 3 axis equipment ? + compatible clamping and fixture systems + custom made fixtures/ fixture plates in-situ. + clever things that can create supports and reference surfaces as part of the part geometry to be machined off later or use of tooling balls etc.<_--- that capability comes about from being able to re-reference parts accurately through the day / thermal temperature changes + super excellent build geometry. "Regular" 5 axis machine processes basic claim to fame is fewer "Screw ups" between set-ups. Other than sim 5 axis geometry.
For 13 years now I've been building injection molds with 3 axis vertical mills. When it comes to making inserts there is always multi sided work that needs to be done. We have always tackled it by doing the back work first, inserting taped and dowel holes where possible and then attaching a fixture plate to it so we can move the fixture plate, and attached insert, to an angle plate or 246 block to manually rotate and do the side work.
Business is changing a little and we are seeing more small batch prototype work that needs the same multi sided ops to complete the parts. Most of these can't have the taped and doweled holes for fixturing so it's a lot of set-ups in the vise to hit all sides. Is there an easier way to approach this than what we are doing currently?
I've been looking into the Fifth Axis self centering vises and their accompanying 90 degree angle plates. Thinking that I could set up the vise on the table to do the top/bottom work then move it to the 90 degree angle plate to rotate through the 4 sides. My fear is that unless I get the vise base indicated in PERFECTLY on the table, I'm going to be off on my side work. Not that big of a deal when playing with +/- .005 for the parts work but when mold inserts have to be held within .0001's, I have my doubts.
I don't have the real estate on my table to dedicate to a 4th axis due to large mold bases going in and out all the time.
How are others approaching this and what might I be missing here?
Thanks.
Ed
Sorta ^^^ leaning into the original post / conundrum. I agree that the EDM "Peeps" have some good solutions in general for not having to buy additionally expensive DD or servo driven rotaries etc., or even lean on Erowa or 3R type pallet system fittings (or at least has been recommended to me in the past.).