CNC machining technology has evolved over the last couple of years from simple machine tools to more sophisticated ones. 5-axis CNC machining is one of the most advanced processes available today. It implements subtractive machining technology to provide infinite possibilities in part creation. This technique uses cutting tools that work on five axes to cut workpieces into desired shapes and sizes.
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5-axis machining offers increased accuracy and precision, efficiency, and reliability. The increased number of axes also gives 5-axis milling machines more outstanding capabilities than their counterparts. Moreover, the process allows complete automation and management with Computer Numerical Control (CNC). As a result, many reliable CNC machine shops rely on this technology for precision CNC machining services.
This article covers the basics of 5-axis CNC machining. Here, we will explain what’s 5-axis machining and how the process works, breaking down the different axes. You will also learn the pros and cons of using this machining process and its common applications. The information we provide will help you get the most out of the 5-axis technology.
This procedure involves the movement of cutting tools across five axes simultaneously. 5-axis CNC machines offer three linear axes working simultaneously with two rotational axes to achieve intricate parts. This typically adds more tilt to the worktable or tool spindly, allowing for increased rotation and movement.
A 5th axis allows machinists to fabricate up to 5 faces in a single operation. This makes the process highly efficient and precise. It also makes it suitable for creating complex structures and features with minimal setups. Since several parts require consistent machining of 5 faces, this process is becoming more valuable for several industries.
To help understand the axes in a 5-axis CNC milling machine, let’s explain what an axis count entails in CNC machining. A machining axis count is the number of directions the cutting tool (or raw material) can move to create the desired product. For instance, conventional CNC machines have three-axis counts. Consequently, their cutting tools can only move across the X, Y, and Z axes.
The cutting tool moves:
5-axis machining centers increase the functionalities of the linear axes by tilting (and rotating) the worktable. There are two additional rotational axes called the A-axis and the C-axis. The A-axis is also referred to as the tilting table axis, while the B-axis is the table rotation axis. Including these axes allows the machining of more complex geometries than 2-axis or 3-axis CNC machines. The table below summarizes the movement of the axes.
As with other CNC machines, 5-axis CNC milling machines rely on computer instructions. The programmed instructions for the machine control the movement of the cutting tool and workpiece. The 5-axis machining process starts with creating the 3D CAD model of the desired components.
After this, the CAD model is exported into CAM software, converting it into a computer program (G-code). The G-code contains instructions for the CNC machine. It contains tool paths created according to the geometries of the desired part. The instructions control the movement of cutting tools along linear axes (X, Y, and Z). It also controls the direction of the worktable along rotational axes (A and B) to create the desired part.
The process allows the machining of 5 faces of a workpiece with one setup. Therefore, it saves manufacturing time and cost, helping you get your products to market faster. But note that the speed and direction of movement depend on the type and configuration of the 5-axis machine.
5-axis machines can enhance your machining procedure and improve scalability. These machining centers can come in various types to meet the manufacturing industry.
The three major types of 5-axis CNC machines are:
Head/Head machines have rotational axes located in the head. Their 5-axis apex comes on a platform that moves through a fixed worktable, keeping the workpiece in place. Therefore, you won’t need to worry about tool interference on the machine spindle head.
This way, the apex has a higher chance of moving around a workpiece, making them suitable for producing large, heavy parts. The machine table can withstand heavy weights without compromising the accuracy of the rotational aces. However, the design of these machines limits their movements in the rotary axes.
Head/Table machine setup has one rotational axis in the head and the other in the rotary table. Their revolving axis has a restricted range and is situated in the head. On the other hand, the rotary shaft has a wider (unlimited) range and is located in the table.
This setup is beneficial because it can consistently rotate the workpiece without any limit. However, there is a limit to the number of parts it can produce. This is because the workpiece rests on the rotary axis.
In this setup, the 5-axis machines have their rotary axes situated inside the table. Therefore, all rotations occur on the table, and the head does not move. The design of these machines makes them suitable for machining undercuts. Moreover, since the head does not rotate, machinists can easily see how the cuts will happen during the programming stage.
However, the machine arrangement is less suitable for machining large or heavy components. This limitation is due to the table’s inability to withstand too much weight.
As mentioned earlier, the movement of axes of the 5-axis manufacturing process depends on the instructions of the CNC program. There are fundamentally two CNC machining operation styles that work with 5-axis:
The trunnion-style machine works with the A-axis rotating around the X-axis and the C-axis rotating about the Z-axis. The movement of the table indicates the rotary axes. That is, both rotational axes are located within the table while the head remains stationary (Table/Table). Trunnion-style 5-axis CNC machines are suited to:
The Swivel rotate style 5-axis CNC machine works with the B-axis rotating about the Y-axis while the C-axis rotates around the Z-axis. This movement differs from the Trunnion style because the table remains horizontal throughout the cutting process. As a result, it can support heavier components. Swivel rotate machines are suited to:
The ability to move the cutting tool and workpiece up to 5 faces at the same time offers several advantages to many industries. It allows the cost-effective and efficient fabrication of complex parts.
Here are the main benefits of this manufacturing process:
A 5-axis CNC machine allows the machining of five surfaces simultaneously. For conventional 3-axis machining, you may need several setups to work on parts with several faces. But the 5-axis technology completes the machining of contoured parts and other parts with many faces in a single structure. This allows you to manufacture components with complex geometries with fewer setups.
The additional rotation in this machining process helps you achieve more complex designs and geometries. The machine allows the seamless machining of arcs and angles that were only previously possible through multiple special fixtures. The 5-axis milling process can rotate parts in a single operation to achieve desired geometries, eliminating the need for complex fixtures.
In addition, the technique pairs excellently with GD&T call-outs to produce datum features in one operation. 5-axis milling is also suited to CNC machining applications requiring surface profile tolerances on complex contoured surfaces.
The extra setups involved with manual machining compared to CNC machining cause machinists to lose precise alignments during fabrication. However, minimal setups involved in 5-axis CNC milling reduce the possibilities for errors and improve the accuracy required to achieve superior quality.
The different types of 5-axis machines available today eliminate the need to re-position workpieces at different angles during machining. Thus, you can be sure of improved machining tolerances. Moreover, some machine configurations allow the use of shorter cutting tools. This increases the lifespan of the tools and ensures repeatability.
5-axis machining ensures that cutting tools are tangential to the cutting surfaces. This arrangement allows the removal of more materials each time the tool rotates. Therefore, it lowers the cycle times and overall machining costs.
The additional axes in this technique ensure proper orientation of workpieces, bringing them closer to the cutting tool. As a result, you can use shorter cutting tools to create desired shapes. These shorter tools can cut at very high speeds with little to no vibration.
Lesser vibration further lowers the chances of getting “chatter” marks on the finished product. The vertical machining process also improves spindle utilization for machining angled surfaces. This way, you can achieve better surface finishes with this technique and reduce costs and time associated with post-processing.
5-axis machined parts are often completed in a single operation because of the high-speed advantage of the process. The single setup involved helps save time and money. Moreover, employing shorter cutting tools with longer lifespans eliminates the need for constant tool replacement, saving money and time.
In addition, the 5-axis milling process can be automated, reducing human operations and labor requirements. This reduces labor costs involved with the process. Therefore, 5-axis CNC machining is a cost-effective solution that accelerates your products to market.
Despite the many advantages of the 5-axis CNC technology, its use is not well suited to some applications.
Some of the setbacks of this process include the following:
The cost of purchasing a 5-axis CNC machine and its essential software is high. It is much higher than what is needed for 3-axis machining centers. Likewise, the maintenance requirements of the machine are also quite challenging than conventional machine tools. This aspect also directly increases the machining costs of 5-axis machined parts.
The two additional rotational motions and the spatial trajectory of their movement are abstract and complex. For instance, to process a free-form surface, you will need to:
All these are necessary to avoid collision and interference and ensure the right amount of interpolation motion. Therefore, getting the desired machining precision, accuracy, and surface quality involves greater programming difficulty.
5-axis CNC milling is an advanced technology involving advanced programming, machine setup, and operations. Therefore, the process requires highly skilled technical operators. This often translates to increased labor costs.
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The under-utilization of 5-axis capabilities is a common occurrence. Some operators do not understand the full capabilities of the machine. Others may not have the programming knowledge for a cutting-edge operation.
The following tips will help you take advantage of the advantages of this manufacturing process:
Before deciding to use the 5-axis technology, try to get enough information. Analyze the data from the customer, checking for accuracy and correctness. Take a close look at the component and check whether there is a need for a pretest.
Simulation software will be useful for verifying the process before translating the CAD design into a CAM model. The software will help monitor the tool’s length, its interference, and the part’s size. It’s needed to invest in programs and software that complement the 5-axis machine’s capabilities. Additionally, it would be best to do a cost analysis to ensure you’re using the most cost-effective process for the job.
Creating 5-axis tool paths often involves a general trade-off between high-speed cutting and reducing risks of crashing. Collisions may lead to defective components, damage the machine, or cause you to scrap parts.
Fortunately, employing certain software tools can eliminate this. The software program will look ahead to check every move of the tool to see if it will run into anything. As long as the CNC machining design is modeled correctly, the software will see the collision before it happens.
5-axis CNC machining ensures high productivity but may also increase the risks of errors. This may be in the form of using the wrong tool or a broken cutting tool. Using a tool-detection system can minimize such errors. This system will help analyze the tool you want to use, ensuring you choose the right one.
Running kinetics will achieve the specifics for every feature with increased accuracy. It will help you understand the right positioning of the cutting tools in relation to the axes’ turning points.
This manufacturing process is suitable for applications in several industries requiring high precision, complex shapes, and tight tolerances.
The typical applications are:
The aerospace industry requires components with organic shapes with contoured edges and compound shapes. Aerospace parts are unique and geometrically intricate, making 5-axis machining the ideal technology of choice. This process achieves a high level of detail and reduces the need for re-fixturing of the cutting head. Thus, parts for aerospace applications remain as precise as possible, meeting industry standards.
Quality and precision are non-negotiable when it comes to manufacturing medical equipment. The high-precision capabilities of the 5-axis fabrication process assist in the production of implants, devices, and other equipment to meet rigorous healthcare requirements. Most of the components are small and intricate. Others are complex electrical scanning and monitoring equipment. 5-axis technology offers an efficient and cost-effective means of producing these components.
The energy industry often requires complex and advanced components, including solar power systems and power stations. The rapid emergence of 5-axis machining ensures CNC precision machining of detailed and specific parts for energy equipment. These parts are machined to be durable and provide stability to workspaces.
Deciding between 5-axis machining centers and other techniques can be pretty challenging. There are many factors to consider to ensure you make the best choice. Here’s a comparison between this technology and other methods.
Many people tend to confuse these two techniques. 5-axis CNC machining, also known as continuous 5-axis machining, involves the continuous rotation of cutting tools along five axes. In contrast, 3+2-axis machining executes a 3-axis program. During this process, the cutting tool is locked at an angle. The two rotary axes determine this angle.
The main advantage of 5-axis over 3+2-axis CNC machining is speed. The latter involves constant stopping and starting of the machine between each tool orientation. However, the former completes the cutting in a single operation. Furthermore, 5-axis machining is more suitable for complex surfaces, while 3+2-axis CNC machining works mainly for plane processing.
Since 5-axis machines require lesser clamps and no special fixture, the machining cost is lower than with 3+2-axis counterparts. However, you should note that the programming involved with the 5-axis technology is much more complicated than the 3+2-axis machining.
Unlike the 5-axis CNC machining process, 3D printing is an additive manufacturing process that involves building components one layer at a time. While these technologies differ in their mode of operation, there are more overlaps in their application. They both offer high accuracy, fast turnaround, increased repeatability, and excellent surface finishes.
3D printing does not require special fixtures or tooling. As a result, the initial setup cost is also minimal. However, 5-axis CNC machines offer better dimensional accuracy than 3D printing. They can machine small and very large parts accurately. Getting extremely tight tolerances with 3D printing will require additional post-processing operations.
With 5-axis machining explained, you now comprehensively understand 5-axis CNC machining. It’s time to take charge of your manufacturing experience. 5-axis CNC machines simplify fabrication processes, ensure faster and cost-effective production, and improve precision and accuracy. However, they are not ideal for all designs. For instance, 3- or 4-axis CNC machines may be more suitable and cost-effective for precise cutouts, holes, and cavities.
Therefore, it is important to contact a CNC machining expert before starting your project. RapidDirect is a leading CNC machining services provider across the globe. We own several 5-axis CNC machines, including Hermle C650, C400, C250, C42, and C22. Our strong 5-axis CNC machining services can manufacture high-precision CNC machined parts with high quality, fast lead time, and competitive pricing.
Our highly skilled technicians also offer technical support to help you choose between our range of machining technologies and production-grade materials. Contact us today, so we can discuss your project. Upload your design file on our instant quotation platform to get an instant interactive quotation with free DFM analysis.
5 Axis CNC Machining is an incredibly versatile machining process that implements subtractive machining technology. Through this process, a workpiece is cut into shape using cutting tools working on five axes to deliver a final part. CNC machining is incredibly popular due to its high accuracy, efficiency and repeatability. The process starts by utilising the original Computer-Aided Design (CAD) file to help program cutting tool paths, all managed via Computer Numerical Control (CNC). Once these tool parts have been programmed into a language that CNC machines understand, the process can be entirely automated, meaning there are minimal manual processes.
This article highlights the features of 5 axis CNC Machining and why it differs from 3-axis or 2-axis machining and notes the benefits of using a 5 axis CNC machine.
Due to the increased number of axes, five-axis milling machines have greater capabilities than their three and two axes counterparts. The machines can be configured in such a way as to reduce the need for constant supervision. Efficiency and single set-up for manufactured parts are the main reasons why industries choose to implement 5 Axis CNC machining.
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In CNC machining, a part is formed using cutting tools and subtractive machining technology, which cuts away at the workpiece to create the desired shape. The shape is predetermined by the original CAD (Computer-Aided Design) file. A program is then produced in G-Code format, which feeds instructions directly to the CNC machine.
Currently, it is most common for CNC Milling machines to have three axes to work from, X, Y and Z. However, 5 axis CNC machines use further axes, to implement into the cutting process from additional angles, giving greater scope for more complicated and intricate designs. So, axes A, B, and C can be introduced.
These axes work alongside X, Y and Z in rotational angles to deliver a 5 axis cutting machine capable of intricate designs while remaining a very high quality to the finished piece. The A, B and C axes move independently to the X, Y and Z in a rotating fashion. The specific configuration of the machine or CAD design determines which two of the three additional rotational axes are used. This 5-axis configuration comes at a higher cost due to the higher levels of calibration and automation technology needed to run the CNC machine and input the commands.
In terms of precision engineering technology, 5 axis machining can offer the best precision engineering solutions, and it is an industry-leading engineering process within the automotive, aerospace and medical industries, to name a few.
The three axes X, Y and Z work in the same fashion and calibration as a 3-axis CNC machine. The movement of the additional two axes working within five-axis machining is always controlled by the CNC program inputting the instructions to the machine.
There are fundamentally two styles of CNC machining that operate with 5 axis:
A Trunnion style 5 Axis machine operates with an A-axis rotating about the X-axis, and a C-axis rotating around the Z-axis. The rotary axes are expressed via the movement of the table. This type is more suited to larger work volumes, as there is no need to compensate for the space taken up by the swivelling handle.
A swivel rotates style 5-Axis machine operates with a B axis rotating around the Y-axis, and a C-axis rotating about the Z-axis. It differs in that the table is always horizontal during the cutting process, meaning it can support heavier parts. The rotary axes are expressed by the swivelling cutting arm.
The cost depends on the project at hand and the volume of parts being produced. Beyond the higher cost of purchasing a 5 axis machine, 5 axis CNC machining requires more significant set-up levels before the production of a component can begin. This higher initial set-up cost during preproduction can make low volumes or one-off more expensive than equivalent parts produced on a 3-axis machine.
This is understandable as 5 axis machines are by their very nature more complex and dynamic than other types of CNC machines with fewer axes. 5-axis milling machines are also more time-efficient, as they are calibrated to complete parts without any need for intervention. Usually, only one operation is needed to complete the workpiece, so downtime is dramatically reduced. Fixturing requirements are reduced, which is mainly beneficial to more organic, complex parts.
The range of motion achievable from the cutting head & extra rotational axes means that these machines can reach five sides of a part. For example, if a geometrically complex part were needed for aerospace, a five-axis CNC machine would be the most capable machine to achieve this. This is due to its ability to reach complex angles and cut areas hard to get, such as a compound curve.
Due to the advanced capabilities of a cutting tool working with five axes, a higher quality finish is achievable, as the cutting tools can be shorter on a 5 axis CNC machine. This reduces the vibration of the tool and as a result, reduces the chance of “chatter” marks and ensures a smoother surface finish on the final part. The time-consuming and costly need for hand finishing can be almost entirely eradicated, as 5 axis machines can closely follow contoured geometry that is traditionally harder to machine.
Due to the high speed of 5 axis machining and increased automation, there is little need for intervention or manual processes. This is commonly known as “done in one” and “one-hit machining”. The multiple axes mean the whole workpiece can be cut in one go instead of the need for several operations to complete the final piece. This, in turn, results in faster output capacity.
5 axis CNC Machining can produce very complex geometries. For example, machining castings and parts that include many different features would, in the past, require a multitude of set-ups to machine and finish the desired shape. However, with a single set-up, 5 axis machining can complete a piece to its exact requirements with only one fixture in most cases.
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