Technology advancements have helped develop more productive machining methods, including simultaneous 5-axis machining and 3+2-axis machining. Some machinists and designers tend to confuse these processes, so we will look at simultaneous 3+2 axis vs. 5 axis machining.
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For many years, traditional manufacturing used machines operating in three dimensions – the X-, Y-, and Z-axis. This type of rotational movement for machining components is still prevalent in manufacturing. However, the newer technologies add two more axes to the conventional three dimensions, giving machines five axes.
That said, it is essential to note that the 3+2 axis mechanism may not exactly equal 5-axis CNC machining. Does this sound illogical to you? This article will extensively examine the 3+2 vs. 5 axis machining comparison. You will also learn the advantages and disadvantages of each process so that you can choose the best option for your operations. Let’s get to it!
The simultaneous 5-axis machining tool moves cutting tools simultaneously across five axes. Three linear axes and two rotational axes work simultaneously to create the desired components.
The axes are:
The additional two axes (A and B) are known as the tilting table axis and the table rotational axis, respectively. As you have seen from the movement of the axes, 5-axis machining involves additional tilt to the tool spindle or worktable. Consequently, there is increased movement and rotation, improving the functionality of the conventional CNC machining processes.
The fourth and fifth axis ensures that machinists can fabricate up to 5 faces in one operation. As a result, the process is highly precise and efficient. In addition, it makes creating complex features and structures more efficient. The minimal setup makes the process highly suitable and cost-effective for various projects.
Vertical and horizontal milling machines have helped reach the usual three machining axes. However, tilt-rotary trunnions and rotary tables have been added for easy movement on two additional rotary axes. This is essentially 3+2 axis machining.
The machining process is also called positional 5-axis machining because the 4th and 5th axes keep the part fixed in a specific orientation. The typical 3-axis machining operation can then be carried out as opposed to continual movement during the process. In addition, the 3+2 axis machining centers use shorter, more rigid cutting tools. Thus, you can be sure of greater dimensional stability.
The 3+2 machining setup adds extra advantages to the traditional 3-axis machine center. It enables the machining of workpieces from all sides. Therefore, it reduces the need for more setups during the manufacturing process. As a result, the cycle time and production cost will reduce.
The major difference between 3+2 and 5-Axis CNC machining is their setup. The 5-axis machining center has a complete design allowing it to move cutting tools in five axes. On the other hand, the 3+2 axis machining uses the 3-axis CNC machine functionality together with tilt-rotary trunnions and rotary tables.
Another difference between 3+2 and simultaneous 5-axis CNC machining is the applicable products and industries. 3+2 machining works majorly for plane processing projects. On the other hand, 5-axis machining is more suited for complex contour surfaces. The capabilities of 5-axis machining allow it to fabricate various parts features and geometries suitable for different industries.
However, not all projects will require the full simultaneous 5-axis CNC machining. Sometimes, the 3+2 axis machining may be more efficient. To determine the best choice between 5-axis vs. 3+2 machining, you need to know their advantages and disadvantages.
There are many benefits of using the 5-axis machining process, including the following:
The minimal settings necessary for 5-axis machining lower the chances of error and enhance the functionalities for CNC precision machining to attain outstanding quality. The 5-axis machines on the market now avoid the need to adjust workpieces at various angles while cutting. As a result, you may expect better machining tolerances.
Cutting tools are usually tangential to the cutting surfaces when 5-axis machining is used. This configuration enables the removal of additional materials as the tool spins. As a result, cycle times and total machining costs are reduced. Furthermore, certain machine setups permit the use of shorter cutting tools. This extends the tools’ lifespan and assures repeatability.
The 5-axis machining center can machine five surfaces at the same time. In a single structure, it completes the machining of curved components and other parts with multiple faces. The extra rotation in this machining method allows for more complicated designs and geometries. The 5-axis milling technique may rotate pieces to reach required geometries in a single operation, avoiding the need for sophisticated fixtures.
This technique’s extra axes guarantee the appropriate alignment of workpieces. Thus, it brings them closer to the cutting tool. Consequently, you may create desired shapes using shorter cutting tools. These tools are capable of cutting at fast speeds with minimal vibration.
Less vibration reduces the likelihood of “chatter” markings on the end product. Some CNC machines also increase spindle usage when cutting inclined surfaces. This technology allows you to create superior surface finishes while reducing post-processing expenses and time.
Because of the high-speed advantage of the method, 5-axis machined components are frequently produced in a single operation. The single setup required saves time and money. Furthermore, using shorter tooling with increased longevity removes the need for regular tool replacement, which saves machining costs and time.
The various advantages of 3+2 axis machining include the following:
The 3+2 machining technique allows the use of even shorter and more rigid cutting tools. These tools allow the fabrication of steep walls, undercuts in cavities, and many other complex features. The cutters can also create specific angles with the cutting surfaces.
At the same time, the spindle head is able to extend lower and closer to the workpiece. Therefore, precision is also achievable with this technique while it increases tooling lifespan.
Unlike simultaneous 5-axis machining, 3+2 machining involves lesser spatial trajectory. Since the tool moving distance is shorter, the rotational motion is also lesser, enabling more accessible programming of free-form surface processing.
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The traditional 3-axis machining centers will require you to stop the spindle multiple times to be able to machine different surfaces. This can be hugely challenging if you need to machine five or more surfaces. The 3+2 CNC machining capabilities help eliminate this issue. With this technique, you can work on five different surfaces at a time.
Although simultaneous 5-axis CNC machining is highly beneficial, it also has some disadvantages. Some of them include:
The price of a 5-axis CNC machine and its necessary software is considerably high. It is far greater than what is required for 3- or 4-axis machining centers. Similarly, the machine’s maintenance needs are more complex than those of traditional machine tools. This factor also directly impacts the machining costs of 5-axis machined components.
In some circumstances, the 4-axis and 5-axis machining techniques cannot be used. Such situations include when the cutter is too short or when the handle is too broad. In these conditions, vibration cannot be prevented under tilted angles.
The additional rotary axes and the spatial trajectory involved are abstract and somewhat complicated. As a result, achieving the requisite machining accuracy, precision, and surface quality demand more programming effort. The machining accuracy error is greater in 4-axis and 3-axis than with the 5-axis machining.
The 3+2 machining technique is generally set at a constant angle to the tool spindle. Therefore, you may need to have many titled views to cover the surfaces of complex CNC components. This often causes an overlap of tool paths, increasing the machining time.
When comparing 5-axis vs. 3+2 machining, you will notice that they perform essentially the same functions. They both have advantages to improving efficiency on any production line. However, the right choice of technique will depend on the specific applications of the desired end results. For instance, 3+2 machining works majorly for plane processing projects. On the other hand, 5-axis machining is more suited for complex contour surfaces.
Machine shops that currently use 3-axis machining can easily transition into complete 5-axis machining capabilities with the means of 3+2 machining. It offers many advanced capabilities of the full 5-axis machines without too much expense. Since the initial costs of 5-axis machines and programming requirements are high, it may be more advisable to employ 3+2 machining.
However, 5-axis machining tools offer increased efficiencies for creating parts with complex geometries and tight tolerance requirements. They tend to meet a wide variety of processing needs with increased productivity and profitability. Their ability to process five surfaces of a component in a single operation involves lesser preparation, better accuracy, and shorter lead times.
Understanding the differences between 5-axis vs. 3+2 machining is great. However, getting superior quality and high-precision components requires working with a reliable CNC machining company. RapidDirect offers you extensive machining capabilities with state-of-the-art facilities, including 3+2 axis machines and simultaneous 5-axis CNC machines to ensure high precision and accuracy of machined parts.
Our advanced technologies help simplify fabrication, improve precision, and ensure fast and cost-effective manufacturing. We boast highly skilled and experienced technicians who are knowledgeable enough to offer outstanding 5-axis CNC machining services. We will recommend the most suitable techniques for your CNC machining projects to ensure you get the best results.
Our technical support team follows your project throughout and solves your problems in time. Contact us now, and let’s talk about your project. You can also upload your design files on our online quotation platform for a comprehensive DFM analysis and instant quote.
These days, CNC technology has evolved to include touchscreen controls, robots, and multiple-axis machines. For those that are brand new to the world of machining and bringing your manufacturing in-house, it’s daunting to figure out what kind of equipment you need. To provide a better idea of which milling machine and capabilities are best for you, we’ll explain the difference between a few types of machining: 3-axis, 4-axis, and 5-axis.
For 3-axis machining, the tool can move in three distinct directions independently or simultaneously relative to the material. It can move in the X, Y, and Z linear directions. In the case of a DATRON 3-axis milling machine, it’s back to front (Y-axis), side to side (X-axis), and up and down (Z-axis).
3-axis machining is great for sheet milling parts like panels and enclosures. It’s often used to make 2D and 2D.5 geometry. If you need to machine multiple sides of a part, that’s possible using multiple setups. Each orientation of the part gets set up and reconfigured in the workholding, which means more time is spent on the setups rather than milling the parts. There’s also more room for error with the fixture and aligning it to make sure the features are milled accurately. However, the DATRON next© control, integrated camera, and touch probe make it easy for even the most complex setups. Since precision and time are important factors in keeping production profitable, 4th and 5th axis machining may be more suitable depending on part geometry.
A 3-axis machine is well suited for operations like drilling, threading holes, cutting key slots, milling undercut features, cutting sharp angles, surface features, and features on the same plane. All these operations can also be done on 4-axis and 5-axis machines; the choice between them ultimately depends on your workflow, application, and budget. Complex geometries can be machined with 3-axis milling, but depending on the part’s geometry, 4-axis or 5-axis machining may be faster or necessary to reach certain features. If you need to make features that are on an angle to the XYZ coordinate system, 4th and 5th axis milling may be quicker and more precise.
There are different variations for 4-axis machining, but we will talk about vertical 4-axis milling. 4-axis machining has the same 3 axes (XYZ) as 3-axis, plus an additional axis for rotation. With a DATRON machine, it’s the A-axis. The A-axis has the workpiece rotate around the X-axis. The rotation allows 4 sides to be machined while the part stays in the fixture and needs only one setup.
There are 2 types of 4th axis milling: indexing and simultaneous (this is also the case for 5th axis milling). Indexing in 4-axis milling, known as 3 + 1, has the workpiece rotate into a position where 3-axis milling strategies are then used. For simultaneous machining, the part rotates, and the machine cuts it at the same time.
More complex geometries, like arcs and helixes, can be achieved more efficiently with 4th and 5th axis machining. You’re also able to cut angled features more easily. However, because the piece is secured in a single setup for 4th axis, the angled features need to be on the same axis. Otherwise, with different angled features, you adjust the setup (and possibly change the fixture) for each angle.
4th axis machining is often used when cut-outs and holes are on the side of a part or made on a cylinder. By using 4-axis instead of 3-axis, you typically save more time because you’re eliminating the need for additional setups. It’s also easier to hold tight tolerances on all 4 sides of a part since it stays in a single setup.
Like 4th axis machines, 5th axis machines also have their variations. The machines typically either use a rotation in the A-axis and C-axis or a rotation in the B-axis and C-axis. Both the workpiece and the spindle rotate in 5-axis milling. The two main types of 5-axis machining are simultaneous and 3+2 index milling.
For simultaneous milling, the cutting tool is in XYZ coordinates at the same time as the other two axes (A and C or B and C). This method allows highly complex 3D shapes and curves to be made. 3+2 does not have the two axes rotating at the same time. Instead, the rotation axes operate independently of each other, and the workpiece rotates to an angle in relation to the cutting tool. 5-axis machining allows manufacturers to create parts that were normally made using molds.
So, does this mean you need a separate machine for each type? Not necessarily. By adding trunnions or rotary axis accessories, 3-axis milling machines gain 4th and 5th axis milling capabilities. This is the case for DATRON CNC machines.
The DATRON neo, M10 Pro, and Cube Series are 3-axis milling machines available for upgrades with DATRON accessories. The M10 Pro and Cube series’ machine beds have cut-out options for 4th or 5th axis accessories. The neo can do 4-axis milling with a rotary axis accessory. There is even a 5th axis DATRON machine, the C5, which is used for micromachining small, precision parts.
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