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 CNC 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 CNC machining really like this?
What is 5 Axis CNC Machining?
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.
What Does “5” in the 5 Axis Stand For?
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.
How Does A 5 Axis CNC Machine Work?
Like every other CNC machine, a 5-axis CNC machine relies on computer instructions to control the motion of the cutting tool (and workpiece) to fabricate the desired part.
The 5-axis CNC machining process starts with the designer creating a 3D CAD (computer-aided design) model of the desired part using CAD tools like SolidWorks and Autodesk Inventor.
Next, the machinist exports this CAD model into a CAM (computer-aided manufacturing) software, which converts the drawing into a computer program (also called G-code).
The G-code contains sets of instructions that control the motion of the cutting tools along the linear axes (X, Y, and Z axes) and the motion of the worktable along the rotary axes (A and C axes) to produce the desired parts.
Types of 5-Axis CNC Machines
The primary difference between types of 5-axis CNC machines lies in the location of their rotational axes.
In some 5-axis CNC machines, the rotation occurs by moving the table, thereby rotating the workpiece. In others, the rotation is achieved by spinning the tool head while the material remains fixed.
Swivel head machines can handle larger and heavier materials since the workpiece does not need to be moved. In contrast, spinning table machines provide greater speed and stability for lighter objects.
1. Rotary Table and Pivoting Spindle Head.
This machine features a B-axis with a 360-degree rotary table positioned underneath the workpiece. It provides a workspace with a diameter of 50 inches and a height of 50 inches.
This machine is ideally suited for components with angled holes, such as turbine housings. These holes are positioned at various points around the outer diameter (OD) of the component.
With this machine’s design, transitioning from one hole to another requires movement in just one axis. In contrast, other types of 5-axis CNC machines would need to move in two or more axes to reach the next hole on a cylindrical component.
However, with a pivoting head and rotary table machine, the apparatus only needs to be angled once to the correct position, and the spindle head must be oriented in the Z, X, and Y axes only once.
Drilling a series of holes thus becomes a matter of retracting, feeding in, and indexing in the B axis to reach the next hole.
This approach results in a more repeatable process. Using additional axes for positioning increases the potential for positional errors.
Another advantage of this machine design is its suitability for larger materials. With fewer rotational axes moving the material, the machine can more effectively handle large parts.
Although the material is rotated around the B axis, this limited movement allows the machine to work efficiently with tall materials.
In contrast, 5-axis CNC machines with both pivots on the table often have constraints related to material size due to their linear movement limitations.
This design allows the machine to operate effectively on very tall cylindrical materials, as the material remains more fixed in place.
2. Double Rotary Table.
This CNC machine features a primary table so large that the A-axis unit can be oriented across a wide range of positions, offering increased flexibility.
Efficient programming requires the programmer to precisely know the A-axis table face’s position relative to the B-axis pivot.
This often means the code is written with the assumption of a specific A-axis position, leaving the operator with the task of aligning the A-axis unit accurately to match these requirements.
This alignment process can be time-consuming and requires careful configuration.
This CNC machine is ideal for components that require machining around the outer diameter (OD) of a cylindrical material, particularly when the component features holes or rings that need to be aligned with the spindle.
The machine is open, which can pose challenges for handling large parts if the axis components are not properly positioned. While it is equipped for 5-axis CNC machining, it has limitations on material size.
When the A-axis component is in place, the material’s volume is restricted by both the swinging around the A-axis and the practical size limits of the material that can be supported by the horizontal table surface.
Nevertheless, the extensive XYZ movement capabilities of the smaller 5-axis unit make this machine particularly well-suited for using long extensions or tools, especially when working at unusual angles.
3. Trunnion Table Machine.
The trunnion setup, also known as a Table-Table configuration, features both rotary axes integrated into the trunnion table, with the machining head remaining stationary.
This configuration is familiar to many programmers and operators because it builds on the principles of standard three-axis CNC machining.
The two rotary axes are often used to position the material precisely, making it straightforward to visualize the machine’s behavior and positioning during the machining process.
The trunnion table machine often provides superior undercut capabilities compared to other setups because the table can tilt further in one direction than a swivel head design.
Additionally, the trunnion setup offers a larger effective work envelope. The table’s ability to tilt and lock into position allows the X, Y, and Z axes to have their full range of motion.
In contrast, a swivel head machine may require some of the work envelope to accommodate the tool length as the head tilts, which can be a limitation, especially when using long tools that significantly impact the work envelope.
The trunnion configuration is also advantageous for heavy metal removal. Since the head remains stationary, it allows for the use of belt-driven or geared spindles, which typically provide more torque at low RPMs.
This stationary head design also reduces the risk of the head moving out of alignment during machining.
4. Swivel or Articulating Head.
This type of machine can be configured in one of two ways: a head-head setup, where all rotational movements are performed by the head while the table remains fixed, or a head-table setup, which features a rotating table and a tilting head.
Generally, these head-table and head-head configurations allow for the machining of heavier materials compared to the trunnion setup.
In this configuration, the table remains stationary, so the entire weight of the material is transferred directly through the CNC machine base to the ground.
This makes the setup highly stable for handling larger parts. Additionally, compared to the trunnion design, the table’s construction allows for accommodating larger materials overall, regardless of their weight.
The rotating head also facilitates the use of shorter or average-length tools since all tool rotations occur above the material.
Benefits of 5-Axis CNC Machining
#1. Accurate and affordable parts.
If you need the most complex parts in one single step, then you must consider 5-axis machining that also lessens the machining time, errors, and costs in terms of tools.
It ensures faster, accurate, and affordable results for your next projects. You can get precise accuracy without compromising the exactness required to maintain quality.
It enables low cycle times when eliminating more material each time the tool passes.
#2. Complex Designs.
5-axis machining offers a range of advantages over 3-axis or 4-axis options, including the ability to create complex parts. This is a key reason why 5-axis machining has become increasingly popular in modern manufacturing.
The ability to assist in complex CNC machining is achieved through the increased range of motion and positioning of the cutting tool that 5-axis machines provide.
This increased flexibility allows for greater precision and accuracy, resulting in more intricate designs that would be challenging or impossible to create with traditional manufacturing methods.
Furthermore, 5-axis machining eliminates the need for multiple machine tools to create complex parts, saving both time and cost in the manufacturing process.
This can result in faster turnaround times, greater efficiency, and increased competitiveness for businesses that adopt 5-axis machining technology.
#3. Higher speed
5-axis machining enables the involvement of shorter cutting tools considering that the head can be dropped and cutter oriented to the surface. You can get higher cutting speed and tool vibration as well as you can expect the best results.
#4. Reduce setup.
With 5-axis machining; you can able to work on different surfaces at the same time. Usually, in the other techniques, you need to do several setups to get the complex geometry through manual rotating.
However, 5-axis machining can reduce all this stress. This advanced method is capable enough to handle parts that are extremely complex from solids.
When it comes to different materials, it can also deal with several raw materials including high-temperature alloys like tool steel, carbon steel, sterling silver, brass, stainless steel, bronze, etc.
#5. Saves time.
This cutting-edge machining solution can able to save your time when it comes to the drilling of holes as this would require a lot of time when utilizing compound angles. With 5-axis machining, positioning the head along the right axis for each hole is simple.
#6. Increased productivity.
One of the most time-consuming aspects of 3-axis machining is setting up a workpiece multiple times because the part needs reorienting.
This is necessary if a part needs to be machined on all or several sides since the cutting tool remains at a fixed angle.
For these 3-axis jobs, a machinist must be physically present to reorient the part when machining on one side is complete, and this human requirement can be a serious bottleneck to productivity.
5-axis machining greatly reduces the need for multiple setups, since the movement of the table or spindle allows the cutting tool to access the workpiece from different angles without removing it from the machine and setting it up again. This results in increased productivity for the entire process.
By leveraging advanced technology and precise positioning of the cutting tool, 5-axis machining can achieve faster turnaround times without sacrificing accuracy or quality.
This makes 5-axis machining an attractive option for businesses looking to increase their efficiency and output, while also maintaining the highest standards of precision and quality.
#7. Shorter cutting tools and improved quality.
A serious disadvantage of 3 axis machining is the need for long cutting tools due to restricted movement.
5-axis machining allows the use of shorter cutting tools since the machine allows the tool to get closer to the workpiece at a better angle.
This has important knock-on effects, such as allowing for faster cutting speeds without risking damage to the cutting tool or increasing undesirable tool chatter, which affects the quality of the part and the ability of the machine to hit tight tolerances.
Use of shorter cutting tools benefits both the machine shop and the customer. The machine shop gets a longer life expectancy for its cutting tools, while the customer receives parts with better quality and surface finish, and can demand tighter tolerances on fine features.
#8. Excellent finishes.
The last 2 axes will help you to position and take the part closer to the cutting tool. It enables you to utilize a shorter cutting tool and you can achieve a better surface finish.
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#9. Cuts mold cavities with ease and precision.
5 axis machining results in higher-quality molds since its added degrees of movement make it better equipped to handle deep cavities when compared to 3 axis machining. The added accuracy of 5-axis also results in a better surface finish on the mold, reducing the need for comprehensive polishing.
Simultaneous 5 axis machining is also ideal for tall core molds and deep pocket molds.
#10. Reduced Labor Cost.
Optimizing production processes can yield a range of benefits for businesses, including reduced labor costs. In the context of 5-axis CNC machining, two key factors that can contribute to this outcome are faster operation and elimination of multiple setups.
By reducing the time required to complete a job, faster operation can lead to a corresponding decrease in the number of labor hours required. This can translate to significant cost savings for businesses, especially for jobs that require a large number of parts or components to be machined.
Eliminating the need for multiple setups can also contribute to reduced labor costs, as it simplifies the process and reduces the number of steps required to complete the job.
By streamlining the process, businesses can minimize the need for specialized labor and focus on achieving greater efficiency in their operations.
The benefits of reducing labor costs in 5-axis CNC machining go beyond immediate cost savings, as they can also free up resources for investment in other areas of the business.
This can enable businesses to reinvest in research and development, expand their operations, or allocate resources to other areas that can help drive long-term growth and success.
#11. Flawless curved parts.
Curved parts like fins and turbine blades are not suited to 3 axis machining — and even less suited to alternative processes like FDM 3D printing, which is notorious for its step-like surface finish.
With simultaneous 5 axis machining, on the other hand, it is possible to machine smooth and consistent curves onto the workpiece, or to machine details onto an already curved workpiece.
By rotating the table or spindle as the tool cuts the workpiece, it is possible to maintain a consistent cutting angle even along a curved edge.
Disadvantages of 5-Axis CNC Machining
1. High initial cost.
The cost of purchasing a 5-axis CNC machine and its basic software is high. It is much higher than what is required for a 3-axis machining center.
Similarly, the maintenance requirements of the machine are more challenging than those of a conventional machine. This aspect also directly adds to the cost of machining 5-axis parts.
2. Programming Difficulties.
The two additional rotary movements and the spatial trajectories of their motion are abstract and complex.
For example, to work with free-form surfaces, you need to change coordinates several times; perform complex spatial geometry operations; and consider the coordination of the axes’ movements.
All of this is necessary to avoid collisions and interference and to ensure the correct amount of interpolated motion.
As a result, programming is much more difficult to achieve the required machining accuracy and surface quality.
3. More demands on the operator
5-axis CNC milling is an advanced technology that involves advanced programming, machine setup and operation.
As a result, the process requires highly skilled technical operators. This usually means increased labor costs.
4. Fully utilizing 5-axis CNC machining
Underutilization 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 cutting edge operations.
Applications of 5 Axis CNC Machining
1. Aerospace Applications.
In the aerospace industry, 5-axis CNC machining is valued for its ability to produce contoured edges and smooth surfaces.
Aerospace components are often geometrically complex, and the precision of a 5-axis CNC machine is crucial for achieving intricate details and interior cuts.
Additionally, the machine’s capability to complete a component in a single pass without repositioning enhances accuracy and efficiency.
2. Medical Device Manufacturing.
In the medical field, 5-axis CNC machining offers significant advantages for manufacturers of implants, devices, and other precision parts.
The high precision of 5-axis CNC machines meets the stringent standards of healthcare production.
These machines are capable of efficiently producing small, intricately detailed components, saving both time and money through improved accuracy and streamlined processes.
3. Military Applications.
5-axis CNC machines are frequently used to manufacture precision parts for military devices.
In addition to their aerospace applications, they produce components for submarines, compressor blades, turbines, smart weapons, sensors, high-performance engine parts, stealth technology, and even nuclear weapons.
While not all components are military-related, nearly half of all 5-axis CNC machines are purchased for projects or contracts involving the American government.
4. Energy Equipment.
5-axis CNC machines are well-suited for producing specific and detailed parts required by the energy sector.
When working with particularly tough or abrasive materials, these machines provide stability, making it easier to shape and cut the material. They also enhance process efficiency and reduce tool wear.
What Are The Five Forms Of 5-Axis Machining?
The primary advantage of 5-axis machining is its capability to produce intricate and complex parts with high precision. This efficiency significantly reduces production time from start to finish. By allowing the cutting tool or work table to rotate, 5-axis machining minimizes the risk of collisions and efficiently handles various part geometries without the need for reprogramming or additional machining.
Most CNC machine centers are based on the traditional 3-axis configuration, consisting of the X, Y, and Z axes. The 5-axis configuration expands on this by incorporating two additional axes, enhancing the tool’s movement and flexibility.
5-axis machines typically include the following five-axis configurations:
- Double Swivel Head Form – With the double swivel head form, two rotation coordinates control the direction of the cutter axis directly.
- Droop Swivel Head Form – The droop swivel head form has the two coordinate axes at the top of the cutter with the rotational axis not perpendicular to the linear axis.
- Double Swivel Table Form – In the double swivel table form, the two rotation coordinates control the space rotation, directly.
- Droop Table Form – With the droop table form, the two axes are on the table, while the axis of rotation is not perpendicular to the axis.
- One Swing, One Rotate Form – The one swing, one rotate form has two rotation coordinates with one on the cutter and one on the workpiece.