Everything
you should know about 5-axis CNC Machine
What is 5 Axis?
In
the world of machining the basic principle is to start with a block of material
and remove the unnecessary bits. With a 5-axis machining process you can move a
tool in five different axes simultaneously.
Basic computer numerical control (CNC) machines remove material using
only three axes, X, Y and Z. The 5-axis
machining tool has two additional axes, A and B, which allows your cutting tool
to have multidirectional capabilities. Each
axis is described here:
X axis = Left and Right.
Y axis = Back and forward.
Z axis = Up and Down.
A axis = Clockwise and
counterclockwise rotation (horizontal plane)
B axis = Clockwise and
counterclockwise rotation (vertical plane)

Advantages of the 5-axis CNC Machine
Switching
to the 5-axis CNC machine for 5-sided machining solves many problems your shop
may be facing. Overall, it saves you time and money. Here are some of the other
advantages:
1.
Reduces lead
time and increases efficiencies due to single setup (sometimes referred to as
“done in one”.
2.
Reduces need
to find qualified machinist, which closes the skills gap.
3.
By tilting
the cutting tool or the table you avoid collision with the tool holder which
also allows better access to part geometry.
4.
Eliminates
excessive setup costs.
5.
Improves tool
life and cycle time which also reduces cost and delivery time pressure from the
customer.
6.
Increases
productivity which makes each part more profitable.
7.
Brings new
opportunities.
8.
Less
programming related costs.
9.
Requires less
fixtures and tools.
10.
More
efficient process for 3-axis parts as well.
11.
Increased
spindle usage.
12.
Optimized
floor space.
13.
Reduced labor
cost per part.
The
5-axis CNC Mill or 5 Axis milling machine offsets the skills gap
because you have more capabilities with fewer machines. This reduces the need
for locating and hiring more skilled employees. Better efficiencies bring
increased productivity because you are no longer flipping parts for a single
setup. It is also easier to switch from one job to another quickly which
reduces pressure from your customers. If you select the right 5-axis CNC
Machine you can basically do more with less.
5-axis
machining also enables shorter cutting tools to be used because the head can be
lowered towards the job and the cutter oriented towards the surface. This
results in higher cutting speeds without excessive loads on the cutter. This
increases tool life and reduces breakages and downtime.
A
higher surface finish is obtained because the shorter cutters reduces vibration
of the tool during deep cores or cavities that you experience with 3-axis
machines. This also removes the need for hand finishing.
You
can also machine extremely complex parts from solid materials that would
otherwise need to be cast. Using a 5-axis CNC Machine for prototypes and small
runs can run much quicker and for a lot less money. This can reduce your lead
times of one or two weeks instead of two months or more if you had to create
castings which makes customers happy.
5-axis
machining can provide huge time savings in the drilling of holes. While this
may seem trivial in comparison to the difficulty of machining a complex core or
cavity, drilling a series of holes with different compound angles is extremely
time consuming. Using a 3-axis machine requires a different set-up and must be
used for each hole. With a 5-axis CNC Machine, the head can be oriented along
the correct axis for each hole automatically, allowing drilling to be completed
much more quickly.
Training for Using 5-axis CNC Machines
Most
customer issues are not a result of an error in the machining, but the lack of
training of personnel and having communication go correctly from the routing to
the machine. The operators must know before they get started that they are
going to have enough tools in the magazine to finish the part.
Programming
a 5-axis CNC Machine is done through a CAD/CAM program, which stands for
computer-aided design & computer-aided manufacturing. CAD/CAM software is
used to design and manufacture prototypes, finished products, and production
runs. An integrated CAD/CAM system offers one complete solution for design
through manufacturing. The machinist or operator is required to learn all the
basics and understand how different metals cut in different situations. It may
be best to start slow and try different things daily to learn the nuances of
the machine in different situations.
Types of Applications for 5-axis CNC Machines
This
method of manufacturing is popular for industries such as aerospace because it
enables the machining of extraordinarily complex parts. Materials may include
carbon fiber, aluminum, titanium and even wood for artistic and design
applications.
There
are two general application categories for 5-axis machining: machining
complex 3D shapes and conventional machining of tilted surfaces.
When
machining complex 3D shapes on the 5-axis CNC Machine, the two rotary axes are
utilized to keep the cutting tool normal to the surface being worked one. In
the beginning of five-axis machining programming for 3D, work was labor
intensive and required the geometry of each workpiece to be transferred manually
from the design to the computer by keyboard. This process has been improved by
using CAD/CAM software to make the process seamless from concept through design
to production.
5-axis
CNC Machines also allow traditional machining on tilted surfaces. Their two
rotational axes enable them to machine sloping planes, a requirement that
requires multiple holdings on a 3-axis machine. They can therefore be used for
many conventional tasks like milling, boring, reaming, tapping, and drilling,
where the task axis is not normal to the machine table. Some training is needed
to operate the machine in this mode, but far less than is required to master
its full 3D capability.
In
both cases, the difficulties related to creating 5-axis programs have been
simplified over the years. Additionally, the two categories have little in
common. A machinist will be able to master the five-axis technology with less
difficulty because he or she must learn only one specific application.
3D Printing VS 5-axis Machining
Also
known as additive manufacturing, 3D printing is considered by some to be in
direct competition, but others feel they will be complementary processes. 3D
printing can allow parts to be designed that could not be designed in the past.
It is more likely the two methods of manufacturing will work together, allowing
the turning or milling machine do what it does best, and the 3D machine do what
it does best.
3D
printing would not be the best choice if you need to mass produce a part,
because it is limited in speed and accessibility. CNC machining offers great
dimensional accuracy as well as many compatible materials include wood, metals,
and plastics.
Both
methods are compatible with a wide variety of materials, however, 3D printing
is more focused on plastics.
Though
both methods are very competent and useful technologies, the most appropriate
one will depend on the material, geometric complexity, manufacturing volume,
and budget. Sometimes the solution may include both.
Summary
This article introduce 5
Axis, 5 Axis Machining, 5-axis CNC Machines and difference between 3D Printing and
5-axis Machining.