5-Axis Aerospace Impeller Machining — Re-tuned by Ai
Quality and repeatability are critical when machining 5-axis aerospace parts. The faster the parts can be cut with the desired surface finish and accuracy, the more competitive your shop will be for future contracts. Avoiding scrapped parts and reworks ensure smoother process management and overall operations. Now, there is a software, created by FANUC, and applicable to all Methods’ machining centers that enable you to achieve the exact surface finish you desire before your tool ever touches the material.
Introducing the FANUC Surface Estimation Tool. This AI-powered software is not a CAM software. It is a true digital twin that replicates real-world surface finish results in digital simulations to accurately check not only the part shape, but also machining quality level. Prior to any real-world cutting, the software precisely estimates a part’s machined surface by using the position data of each axis then simulating the cutting to detect machining issues. Knowing this before cutting helps avoid wasting valuable time and materials that otherwise might be produced with marks or other surface defects1.
The following highlights a collaborative project demonstrated at IMTS 2026 on the Methods Automation RoboDrill K900 5-axis machining center. This demo was completed in partnership with FANUC America, Concepts NREC, Emuge Franken, and HWR USA Workholding.
the part — a complex 5-axis aluminum impeller
Tight-tolerance, 1mm thickness blade geometry machined complete in a single 5-axis simultaneous setup. No manual repositioning, no secondary operations.
Confirmed on the Part
AXIS REVERSALS — FROM SCREEN TO SURFACE
Reversal points shown in MAX-PAC CAM software also show up in the same locations of the finished blade before machine tuning.
REVERSAL POINTS INSIDE BLADE SURFACE
REVERSAL POINTS OUTSIDE BLADE SURFACE
The Data
PATH ERROR & AXIS REVERSAL ANALYSIS BY FANUC SURFACE ESTIMATION SOFTWARE
PATH ERROR: TEST 1 – BLADE SURFACE
AXIS REVERSAL (B) – REVERSAL POINTS, (B) AXIS
AXIS REVERSAL (C) – REVERSAL POINTS, (C) AXIS
The Process
DIALING IN PERFORMANCE WITH FANUC Ai SERVO TUNING
The Process
DIALING IN PERFORMANCE WITH FANUC MACHINING MODES
The Result
FASTER, MORE ACCURATE — SAME PROGRAM BEFORE AND AFTER Ai SERVO TUNING AND HIGH-SPEED MODE ADJUSTMENTS
INITIAL SURFACE ESTIMATION
SOFTWARE ESTIMATE
INITIAL ACTUAL PART
TEST 5 (FINAL) SURFACE ESTIMATION
SOFTWARE ESTIMATE
TEST 5 (FINAL)
ACTUAL AND FINAL PART
Going Further
TWO MORE LEVERS ON EVERY 5-AXIS PROGRAM
BALL CENTERING PROGRAM
Switching from ball-tip to ball-center toolpaths enables TCP rotation-axis compensation for tighter contour control through complex blade geometry.
STC+ SMOOTH TOLERANCE CONTROL
Smoothens the tool path within a set tolerance and rounds corners in-process. This reduces mechanical shock and shortens overall cycle time.
