---

---

“Tabbing” is a common 5-axis machining strategy where you machine a complete workpiece in a single operation. This approach eliminates additional operations and the need to manually reposition the workpiece, and provides three key benefits:

1.      Improved machine tool productivity

2.      Reduced risk of misloads and scrap

3.      Improved throughput

How Does Tabbing Work?

Tabbing is done by machining all six sides of the workpiece in a single machining cycle. At cycle completion, the workpiece is only attached by a small tab that the machinist can easily break off after unloading the machine tool. The workpiece is now complete, and only minor secondary operations, such as sanding or deburring, are required to remove any remnants of the tab.

There are 4 Critical Factors to Successful Tabbing

To successfully complete a machining process using the tabbing strategy, there are four factors that you need to consider.

1. Tab Location

Selecting the correct face to use for the tab is critical to success. Ideally, the tab would be connected to a face with no features that need to be machined. If all six sides require machining, then you must identify a face that can accommodate the tab, and you can access all the required features from the underside. Cutting tool access will become the defining constraint in this case. If no side of the workpiece can provide access to all required features while allowing a tab, then tabbing is not viable for your workpiece.

2. CAM Software

Once the tab location has been chosen, the next step is to confirm that your CAM software supports tabbing and provides toolpath strategies that can safely machine around the tabs. Not all CAM software treats tabbing the same way, so it is important to verify that your CAM software accommodates this strategy without manual intervention.

3. Workholding Setup

For tabbing operations, cutting tool access is critical, and your workholding setup must be designed for maximum cutting tool access. Utilizing DynoMount risers or pyramids elevates the workpiece above the machine tool table, increasing clearance and improving cutting tool access. Selecting the right self-centering vise can make a substantial difference; Mate offers multiple DynoGrip self-centering vises with a chamfered body design for extra clearance, improving cutting tool access without compromising rigidity.

4. Tab Geometry

Selecting the correct tab geometry, specifically thickness and width, will affect your success. Tab geometry is a balancing act: The tab must be thick enough to provide sufficient rigidity to hold the workpiece securely, but thin enough to be easily removed with minimal post-processing. The optimal tab size depends on several variables, including material type, workpiece size, and machining forces.

Generally speaking, smaller workpieces, harder materials, and lower machining forces require thinner tabs, while larger workpieces, softer materials, and higher machining forces require thicker tabs.

How Mate Supports Successful Tabbing

Successfully creating a machining process using the “tabbing” strategy for five-axis machining applications can improve your quality, productivity, and profitability. Mate workholding provides the products and performance necessary to create a successful workholding setup for tabbing applications. Mate workholding application specialists can help you create a workholding setup for any tabbing application.

Contact your local Mate representative to help tackle your most difficult challenges today!