5 axis CNC machining is a versatile and advanced manufacturing process that is applied in numerous industries due to its ability to produce complex geometries and precise parts fast. This machining method enables the cutting tool and workpiece to move in five different axes, creating complex geometries with high precision and superior surface finishes.
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In this article, learn how 5 axis CNC machining works and its applications, benefits, and limitations.
5 axis CNC machining is a machining setup in which the workpiece and cutting tool can move in five axes. In CNC machining, a cutting tool selectively removes portions of a block of material until the desired object forms. During this process, the machine head and worktable move the cutting tool and workpiece, respectively, to give the cutting tool access to different areas of the workpiece. The direction and orientation of these movements constitute the machining axes. The image below shows a form of 5 axis CNC machining.
As the name implies, 5-axis CNC machining covers five machining axes, three linear and two rotational. The linear axes are the X-axis (left to right movement), Y-axis (forward and backward movement), and Z-axis (up and down movement). Depending on the machine, the two rotational axes are any two out of the A-axis (rotation along axis X), B-axis (rotation along axis Y), and C-axis (rotation along axis Z). For example, a type 5-axis milling machine may be capable of movement in the X, Y, Z, A, and B axes, while another model can move in the X, Y, Z, B, and C axes. The axes described are in the image below.
5 axis CNC machining is a step up from the more conventional three-axis machining in which the workpiece and the cutting tool move in three linear axes. This advanced machining process is faster and more capable than 3 to 4-axis machining. However, it is also more complex, requiring more advanced tool path programming. In addition, it can be twice the cost of 3-axis milling due to the cost of the machine and the complexity of the process.
Different types of 5 axis CNC machining techniques and machines exist. These machines can be classified according to the timing of the movements and the machining operations. The types of 5 axis CNC machines, according to this category, are:
Also known as 3+2-axis machining, the key distinguishing characteristic of indexed 5 axis CNC machining is that the movement is not continuous in all five axes. During machining, the machine continuously cuts in the three linear axes. These movements are part of the cutting operation. On the other hand, the two rotational movements serve to reposition the cutting tool or workpiece. The cutting process stops temporarily during rotation.
In summary, cutting proceeds on three linear axes. When necessary, cutting stops, and the machine repositions the cutting tool or workpiece, rotating by a specific angle. Cutting then resumes along the three linear axes in the new position. These steps occur rapidly and continue intermittently till the part forms. In most indexed 5 axis CNC machine configurations, the table provides the rotational motion, typically in the A and C axes, while the cutting head executes the linear motions. Indexed 5 axis machining is less expensive than its continuous counterpart but 65% more costly than conventional 3-axis milling.
Similar to their indexed counterparts, continuous 5 axis CNC machines can move in five axes. However, unlike indexed machines, continuous 5 axis CNC machines can move in all five axes without stopping. This means there are no pauses in the cutting process for the machine to reorient the workpiece or cutting tool.
The cutting tool continuously engages the workpiece as it moves and rotates in all five axes, creating a smooth, uninterrupted workflow. Continuous 5 axis CNC machining is faster and more capable than indexed machining, as it provides easier access to the workpiece and doesn’t have pauses. Conversely, it is more complex, requiring more sophisticated tool paths. In most continuous 5 axis CNC machines, the spindle provides rotational motion. The spindle or table may execute the linear motions. Continuous 5 axis machining is twice the cost of 3 axis milling.
5 axis CNC Mill-turning centres combine a lathe machine and a milling machine. Capable of both CNC milled parts and CNC turning operations, this hybrid machine produces more complex geometries than the individual machines can.
5 axis CNC Mill-turning centre
In most 5 axis CNC mill-turning centres, the spindle-mounted workpiece rotates along the A-axis. At the same time, a milling cutting head provides linear movement in the X, Y, and Z axes and rotational movement in the B-axis. See our What is CNC turning guide to learn everything you need to know about this process.
The table below compares the capabilities, pros, and cons of common CNC machines and machining operations.
Manufacturers use 5-axis CNC machining services to create highly complex and precise parts for numerous applications across various industries. This operation is often used when highly complex geometries, precise details, and speed are required. Industries that use CNC 5 axes machining include:
Generally, 5 axis CNC machining is an indispensable technology in industries where precision, efficiency, and quality are crucial.
5 axis CNC machining’s ability to produce complex part geometries with precision meets the stringent accuracy requirements of the aerospace industry. Components, such as turbine blades, structural airframe parts, and engine parts require the accuracy and quality that 5 axis machining provides. In addition, the ability to machine complex shapes in a single setup further reduces errors and enhances the reliability and performance of aerospace components.
Precision is especially critical for transmission and engine components in the automotive sector. These components typically have complex geometries and are in continuous motion relative to each other. 5 axis CNC machining meets the demands required for these conditions, allowing for intricate designs and maintaining tight tolerances. This leads to improved performance, efficiency, and customization in vehicle manufacturing.
Medical prosthetics and implants typically have intricate geometries that replicate body parts. An additional layer of complexity is added when these prosthetics are custom-made to fit specific patients. Furthermore, high accuracy, extremely tight tolerances, and quality surface finish are critical to the functionality and safety of medical instruments, implants, and prosthetics. 5 axis CNC machining is one of the few manufacturing processes that meet the rigorous standards of the medical industry, making it indispensable in the industry.
The energy sector, including oil and gas, wind, and solar power industries, benefits from the robustness and precision of 5 axis CNC machining. Components such as turbine blades, pump housings, and complex brackets require durability and precise engineering to operate effectively under harsh conditions. The capability to machine complex parts accurately in one setup makes 5 axis CNC machining ideal for these applications.
5 axis CNC machining provides the necessary precision and capability to produce complex, specialised parts that meet the stringent requirements of military applications The defence industry demands high precision and reliability for components used in weapons systems, vehicles, and aircraft, as errors in these components can have grave consequences.
The flexibility of 5 axis CNC machining makes it invaluable for rapid prototyping and custom manufacturing. Designers and engineers can quickly create detailed and accurate prototypes, allowing for faster iteration and innovation. The ability to machine complex shapes in a single setup without the need for multiple fixtures or repositioning reduces production time and costs, making it an efficient choice for custom parts production.
The ability to move in five axes gives 5 axis CNC machining numerous beneficial characteristics. Some of these are as follows.
5 axis CNC machines can produce very complex geometries. Many of the geometry restrictions that are inherent in 3-axis machining stem from the inability of the cutting tool to reach certain areas of the workpiece and make complex cuts. 5 axis CNC machining overcomes this problem, allowing it to produce highly complex geometries. Provided you create a design according to CNC machine design guidelines. 5 axis CNC machining can create it.
5 axis CNC machining can produce complete parts in one cycle and seldom requires pauses or breaks to reposition the cutting tool or workpiece manually. The increased automation results in a 30-40% decrease in production time and effort. Note, however, that these advantages are only obtainable in low-volume production. Machining time and effort increase exponentially in medium to large production runs.
The availability of the additional axes reduces vibrations during machining, allows for the use of more precise tools, and allows the cutting tools to be closer to the workpiece’s surface. These factors contribute to a higher-quality surface finish.
While 5 axis machining is predominantly beneficial, it has the following inherent limitations.
The initial setup cost of 5-axis machining is relatively high, with the 5 axis CNC machine price of a high-end industrial unit reaching up to £150,000 - £1,000,000. Their use is mostly practical for geometries that cannot accurately be machined via 3-axis machining. Compared to 3-axis milling, Mill-turning operations typically cost 25% more, Indexed 5-axis machining 65% more, and continuous machining 100% more.
The difference in cost between indexed and continuous 5 axis CNC machining stems from the difference in the builds and complexities of their machines. Indexed 5 axis machines are less complex than continuous 5 axis machines. In these machines, the cutting operation occurs in three linear axes while the rotational axes serve to reposition the workpiece. The cutting pauses for rotational repositioning and resumes immediately after. Conversely, in continuous 5 axis machines, cutting proceeds in all five axes concurrently.
The additional two machining axes significantly increase the tool path programming complexity of 5 axis CNC machining operations.
By reaching multiple areas of the workpiece, 5 axis machining creates parts faster than 3 axis machining for one-off and low-volume production. However, machining time, effort, and costs increase exponentially for larger production volumes. Due to the motions used in 5 Axis machining, the machines typically cut one part at a time. Therefore, an operator has to load and unload the machine for each individual part. This is in contrast to 3 axis machining, where multiple parts are machined simultaneously
The necessity of 5 axis CNC machining for your project predominantly depends on the complexity of your part. Geomiq offers advanced CNC machining services that are highly capable, fast, and compatible with numerous CNC machining materials. Simply head over to our instant quoting platform to upload your part, and our team of manufacturing experts will determine the best machining technique for your part. You can also contact us to request 5 axis CNC milling specifically
Over the last couple of years, the concept of machining has evolved. The world has moved from simple machining processes and tools to more advanced and sophisticated ones. One of the most advanced machining processes available today is 5-axis machining.
However, when sometimes mentioned about the specific 5-axis CNC machining, the first impression that comes up to most people’s minds is: high technology, expensive price, and difficulty to operate, but is the 5-axis machining really like this?
Read on as we provide answers to this question and other important information about this machining.
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This type of machining relies on a tool moving in five different directions around which the tool rotates. It is a multi-axis subtractive manufacturing process in which the machine shapes the workpiece material and moves in 5 directions or vertically.
The directions of movement include; X, Y, and Z, as well as A and B. 5-axis machining allows operators to approach part machining from all directions and axis in a single operation. Therefore, eliminating the need for manual workpiece repositioning between operations. Also, it saves time and is ideal for creating highly complex parts requiring precision.
The 5 in 5-axis means that asides from the conventional 3 axes, X, Y, and Z, machines used for 5-axis machining add two more axes making it a total of 5 axes. The 4th axis is the A axis which denotes a rotation around the X axis, while the 5th axis is the B axis, denoting a rotation around the Y axis.
This additional axis enhances the type of work a machine can undertake and the level of detail it can cut.
There are a couple of operations where 5-axis CNC machines can save much of your time and enhance your current procedure. These machines come in several types to meet the requirements of the ever-growing manufacturing industry. A unique difference in 5-Axis CNC machines is the arrangement of the rotary axes.
In this type of CNC machine, the head houses its rotary axes. In this part, you do not need to worry about tool interference of the machine spindle head since the 5-axis apex is on a particular platform. Another reason not to worry about interference is that this 5-axis apex moves through a fixed table that ensures the workpiece remains in place.
This type of 5-axis machine design allows the apex to move around a particular piece during machining. Therefore, Head/Head CNC machines are ideal for producing large parts. However, along the rotary axes, this design has limited movement.
In this setup, there are also two rotary axes, one rotary axis is on the head, and the other is on the rotary table. Located in the head is the revolving axis, and due to the position of this axis, it has a restricted range. On the other hand, there is no limit on the scope of the rotary shaft placed on the table.
One advantage this setup has over the Head/Head is the lack of worry about reaching a specific limit because the parts are consistently revolving. Conversely, since the part or workpiece rests on the rotary axis, the CNC machine’s design limits the number of items it can produce.
This setup has both rotary axes on the table. There is a serious limitation to the scope of the revolving axis here, but there is no limit to the range of the rotary axis. This makes this type of machine ideal for machining undercuts. Also, compared to other machine arrangements, Table/Table has a minimal work envelope.
Additionally, it is slower than other machines since it does not come fitted with definite motors that make the other machines work fast. It is also less suitable for machining large or heavy components since they cannot carry much weight.
The ability of this type of machining to work on 5 different faces of a workpiece simultaneously offers several advantages to many industries. These benefits range from cost efficiency to effective machining. Here are the major benefits of 5 Axis CNC Machining.
The additional axis added to this machine makes machining designs and geometries with high complexity easy. Also, machining difficult angles and arcs, which is previously achievable using multiple special fixtures, has become feasible with 5-axis CNC machines. In addition, the ability of this machine to rotate parts during a single operation makes it possible to achieve desired geometries with the need for complex machines or fixtures.
Manual machining operations require extra setups for optimal machining. But these extra setups often introduce design variability and error, causing machinists to lose alignment during machining. However, 5-axis CNC milling involves minimal setups, eliminating the possibility of errors while improving accuracy.
Also, with most 5-axis CNC machines used by machinists today, there is no need for manually repositioning the workpiece during machining. This guarantees improved machining tolerances. What’s more, using shorter cutting tools in some machine configurations improves tool lifespan while ensuring repeatability.
The process of setting up a 5-axis CNC machine is relatively easier than setting up a 3-axis machine. The reason is that 5-axis CNC machines allow work on five surfaces simultaneously. Moreover, 5-axis machines enable the machining of contoured parts with a single structure. However, for conventional 3-axis machines, several setups are necessary to work on several faces.
The surface finish with a 5-axis CNC machine is smoother due to the presence of additional axes. These additional axes bring the workpiece closer to the cutting tool, making it easier to achieve desired shapes. It also allows the use of shorter cutting tools for machining.
With shorter cutting tools, there is little to no vibration, which reduces the incidence of marks on the surface of finished products. Moreover, there is an improvement in spindle utilization for machining angled surfaces when employing the vertical machining process.
The 5-axis machining can effectively reduce the machining time and auxiliary time of the parts. It has a large range of spindle speed and feeds rage, allowing the machine to perform a powerful large cutting capacity. 5-axis CNC is entering an era of high-speed machining. The rapid movement and positioning of 5-axis machining and high-speed cutting processing reduce the turnaround time for semi-finished products.
The 5-axis offers many advantages and importance in making parts. However, it is not all rosy with 5-axis machining, as there are some drawbacks too. Below are the drawbacks associated with 5-axis machining;
The cost of acquiring a 5-axis CNC machine is quite higher than that needed to purchase a 3-axis machine. The same goes for the software needed for operating this machine. Also, maintaining 5-axis CNC machines is more difficult than maintaining CNC machines. Therefore, the cost is one of the major drawbacks of using 5-axis CNC machines for machining.
The programming needed for 3-axis machines differs from that required by 5-axis machines. This is primarily due to the addition of two rotational motions, which complicates the trajectory of the synthetic motion formed.
For instance, programming the 5-axis would have to consider each axis’s respective motion to avoid collision and interference. Also, achieving better surface quality and precision requires more complex programming.
5-axis CNC machining involves the use of advanced technology. Therefore, a highly skilled technical operator is necessary to get the best out of the machine. However, employing a highly skilled operator also increases labor costs.
5-axis CNC machining results in the production of a variety of parts. These parts often have complex geometries and intricate shapes. Here are some parts you can machine using 5-axis machining.
Complex surface parts are parts you often find in different fields, including aviation, aerospace, electronics, etc. Achieving this complex surface using ordinary CNC machine tools is difficult. Common complex surfaces 5-axis machining helps produce include spherical surfaces, blades of turbine engines, marine propellers, impellers, etc.
5-axis CNC machining is also ideal for machining UAV parts. It is suitable for machining plate parts and plats, especially those with end-face distribution holes or radial holes. It is also suitable for making machine motor covers. It is important to note that applying 5-axis CNC machining to such parts requires the use of either horizontal machining or vertical machining center. The machining center chosen is dependent on the specific hole direction.
Using ordinary machining tools for box-shaped parts is relatively difficult due to the multiple clamping and alignment required. A 5-axis machine’s ability to work on several surfaces simultaneously makes it easier to produce higher-precision box-shaped parts.
The special shaped parts refer to parts with irregular shapes. For instance, workpieces with mixed points, surfaces, and lines. Machining such parts with conventional machining are difficult or close to impossible due to the difficulty in controlling the clamping pressure during the process. However, with 5-axis machining, it becomes easier to complete the process using a multi-station point.
Since most operators do not know the full capability of a 5-axis CNC machine. So, here are some strategies that could help you get the most out of a 5-axis CNC machine.
Before jumping on a 5-axis CNC mill, you must get the right information. Getting the right information involves analyzing design data for accuracy and correctness. Verifying the design process before translating the CAD design into its CAM equivalent is also important.
With the right information, selecting the ideal CAD/CAM software and controls is possible for accomplishing the design task. The software is a simulation software for monitoring the part size, interference, and tool length.
Also, with this information, it becomes possible to undertake a cost analysis to ensure using the right and most cost-effective process for the job.
Using the wrong tool for the job increases the risk of errors. Besides, the wrong tool would wear easily, or break during machining, consequently increasing the cost of production and reducing product quality. One way to mitigate this is by using a tool detection system. This system helps you analyze the tool you want to use, ensuring it is the right one for the job and minimizing errors.
Collisions lead to defective components or a damaged machine. Fortunately, there are software tools that can help mitigate this risk. So, how does it work? This software simulates the design process and often sees the collision before it happens, providing a way to change the design command. There are many of this software but the popular ones include Predator and ModuleWorks.
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