Why is 5 Axis CNC Machining Service Better?

CNC machining is a subtractive manufacturing method that removes material using computer-controlled, precision machines with a wide range of cutting tools to achieve an intended design. CNC machines come in three main kinds including horizontal milling machines, vertical milling machines, and lathes.

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CNC machines are highly effective manufacturing solutions because they use pre-programmed computers to determine precise movements of the tools. These programs operate based on instructions that are entered into the CNC machine using encoded CAM (computer-aided manufacturing) software.

5-axis CNC machines have two additional axes compared to traditional 3-axis machines. With a 5-axis machine, the cutting tool can cut the part along five directions instead of three. These additional axes provide increased movement and rotation during manufacturing. Let’s take a closer look at the 5-axis CNC machining service.

5-axis machining offers the unique of advantage of the fact that the mill and the part can be moved in as much as 5 ways at the same time around multiple axes. As a result, 5-axis machining enables complex parts to be produced in a cost-effective manner.

Here is a closer look at the advantages of 5-axis CNC machining:

• Reduced number of setups. 3-axis machining requires multiple setups to achieve the desired geometry by manually rotating the part if it requires machining on multiple faces. With a 5-axis machine, fewer setups are required to manufacture a part with complex geometry.
• Can avoid the need for complex fixtures. Complex fixtures must often be used to hold the part in its required orientation during 3-axis machining. As a result of two additional axes, 5-axis machining allows manufacturers to avoid creating these fixtures since the workpiece is held at one location on the part and rotated to produce the geometry.
• Increased efficiency of material removal. 5-axis machining enables the cutting tool to be tangential to the cutting surface. As a result, shorter cycle times and lower costs are possible since an increased amount of material is removed with each pass of the cutting tool.
• Superior surface finishes. During 3-axis machining, lots of smaller cuts must be done to produce a desired surface finish, which adds on costly lead time. In contrast, since 5-axis machines are superior on contoured geometries, a far better surface finish can be produced.

5-axis machines add to the three linear axes on traditional 3-axis machine by tilting and rotating the table holding the workpiece. These two additional rotational axes are called the tilting table axis (A-axis) and the table rotation axis (B-axis).

In total, 5-axis machines use five different directions (or axes) commonly called X, Y, Z, A, and B. The G-code instructions for the 5-axis CNC machine control the movement of the cutting tools along the X, Y, and Z axes and the motion of the worktable along the A and B axes to manufacture the intended part designs.

Here is a summary of the 5 axes:

• X - Left to right
• Y— Front to back
• Z— Top to bottom
• A— Titling table
• B — Table rotation

As a result of the extra axes, up to five faces of a part can be machined in just one operation. These qualities make the process extremely efficient and precise. For these reasons, 5-axis machines are ideal for parts that include complex movements and intricate geometries that would otherwise require lots of setups. As part designers create increasingly complex parts, they require at least five different faces to be machined, which means that 5-axis machining is increasingly a go-to solution for CNC manufacturing.

Compared with traditional 3-axis machining, 5-axis CNC machining allows the workpiece to be worked on five axes rather than just three. Although traditional 3-axis machining is still versatile and useful for certain projects, 5-axis machining is superior for parts that have more complex designs. That being said, if only one flat surface needs cutting, 3-axis machines could be the best option in terms of affordability. Moreover, 3-axis machines are easier to program, so the cost of using expert CNC programmers is removed.

5-axis CNC machines provide high levels of accuracy and geometric precision. Not only do they achieve these accuracy levels when machining deeper parts and hard-to-machine materials, but they can also meet very strict tolerance requirements.

Since 5-axis machines provide an amazing amount of movement and flexibility, they are much more precise and able to meet tight tolerances compared to other manufacturing methods. For these reasons, 5-axis CNC machines are a great manufacturing solution for achieving tight surface profile tolerances on contoured surfaces with complex geometries.

In the precision manufacturing industry, machining technology continues evolving from punch-controlled 3-axis CNC machines to more sophisticated 5-axis machining solutions.

A report by Technavio has projected the 5-axis CNC machining market to grow at a compound annual growth rate of nearly 6% between and , citing Methods partner FANUC as a leading 5-axis machine manufacturer.

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The need for self-optimized machine cutting is one of the significant factors driving this growth in 5-axis machining, in addition to higher accuracy and greater precision for tighter tolerances, and increased efficiencies for automated operations.

Shop owners should consider 5-axis solutions when evaluating their current lineup of machines and operations. The benefits delivered by 5-axis machine tools can offer shops a competitive advantage through optimum cycle times, precision, and overall customer satisfaction.

What are the Five Axes in 5-Axis CNC Machining?

A CNC axis count refers to the number of directions a CNC machine tool can move to produce desired parts.

Here are the five axes upon which a 5-axis machine tool can move:

• X-axis
• Y-axis
• Z-axis
• A-axis
• B-axis

Take the case of conventional 3-axis CNC machines, which naturally have a three-axis count. 3-axis machines can move sideways on the X-axis, up and down on the Y-axis, and back and forth on the Z-axis.

Beyond the three linear axes, 5-axis CNC machines add two axes, typically called the A-axis and B-axis. These two additional axes enable 5-axis machines to tilt and rotate the cutting equipment or parts to produce more sophisticated geometries than 3-axis machines.

These make 5-axis machines the secret to producing highly precise components without seams or signs of welding. 5-axis machining capabilities have transformed manufacturing industries, such as automotive, healthcare, aerospace, and agriculture.

6 Benefits of 5-Axis Machines

Investing in 5-axis CNC machining produces greater productivity and improves numerous manufacturing metrics, delivering a measurable and significant ROI through these advantages:

1. Higher Precision and Accuracy

5-axis CNC machines operate with greater precision to deliver accurately machined and smoother parts that would be too complex for machining on traditional 3-axis CNC equipment.

2. Improved Production Speed (Lead Times)

The tangential arrangement of the cutting tools to the material removes more material with each rotation. When 5-axis tools are combined with the machine’s single setup, cycle times improve significantly.

3. Fewer Setups

With 5-axis machines, you can set up your workpieces at one time to handle all milling operations needed to fabricate complex geometries. You’ll produce parts faster, minimize operational costs, and reduce most errors prevalent in conventional 3-axis machines.

4. More Complex Part Geometries

The ability of 5-axis CNC machining to move workpieces over more dimensions without removing them gives it a significant advantage over conventional 3-axis machining. These machines attack the most complicated angles to create complex geometries with premium finishes with tighter tolerances.

5. Better Surface Finishes

The fourth and fifth axes (A-axis and B-axis) on 5-axis machines bring the work material closer to the cutting tool. Shorter cutting tools produce better surface finishes because the shortened length makes them less susceptible to machining vibration.

6. Improved Drilling Capabilities

5-axis machines change the game for drilling applications because of the additional axes that allow the machine to reach tighter and more complex angles, producing parts with finer finishes.

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