Advantages of 5-Axis Machining

One  type  of CNC equipment that is growing in application is five axis machines. These  machines are ideally suited for producing complex shapes and sizes of machined components. There is a demand in all phases of the aerospace markets for  tighter tolerance and better finishes. The advantages of 5-axis machines is they are designed to address the tolerance, finish, and setup challenges. 

Thanks to the advances in control, servo, and tooling technology, the abilities for producing complex 5-axis machined shapes becomes a reality. Because of the inherent advantages of the 5 axis design it lends itself to simpler work holding,  fewer setups, and greatly reduced tolerance stack-up. It many applications you can now produce very complex shapes in a single setup. 

Definition of 5-Axis Machining

Traditional CNC machines move in two linear axes (X and Z) for lathes and three linear axes (X, Y, and Z) for machining center. The term “5-axis” refers to the number of directions in which the cutting tool can cut. On a 5-axis machine, the cutting tool moves across the X, Y, and Z linear axes as well as rotates on the A and B axes  which enables it to approach the workpiece nultiple directions.

The ability to produce complex shapes without having to move the part across multiple machines offers significant advantages over previous conventional two-three-four axis machining.The benefits of 5-axis CNC machining can be significant.

Improved Tool Life

Improved tool life and cycle time are a result of being able to program the tool and/or table which enables the machine to maintain optimum cutting position and constant chip load, throughout the machining process.

Complex Shapes

The major  advantage of 5-axis machining is the ability to machine complex shapes, while minimizing the number of chucking or fixturing positions. The additional  movement creates machining angles and arcs for the cutting tool and allows chip relief. This was only previously possible by using multiple with special work holding fixtures as well as additional setups.

Fewer Setups

Five-axis machines can machine all visible surfaces, excluding the bottom or clamping area. This ability significantly reduces the need for multiple setups and special fixtures. Depending on the workpiece and machne configuration, you can reduce the number of setups to one.

Relational Accuracy

Tolerance stack up (imprecision) is one of the results and challenges every time you have to move the part for re-chucking or fixturing. Once a part is removed from the work holding device, alignment and geometries can be lost.  Minimizing the number of work holding placements helps maintain the zero or home position location and feature – to – feature accuracy is improved.

3+2 Axis Machining

There are parts that can only be successfully machined using full 5-axis simultaneous movement, but not all parts require the simultaneous 5-axis movement. Some parts require five axes, but not simultaneously. Some “5” axis offer 5 axis but not simultaneous, usually 3 + 2 or 4+1.

In three + two or four + one machining, the fourth and fifth axes are used to locate the workpiece (or cutting tool, depending on the type of machine) in a fixed position. In these scenarios, there is no need for all five axes to move simultaneously.The same tool paths can be achieved in a three-axis machine, but only after loading and unloading between multiple setups, fixtures, or machines.

Better Surface Finish

Using the rotating fourth and fifth axes, the part can be orientated to bring it closer to the cutting tool. By putting the part closer to the cutting tool the work piece is less susceptible to vibration, which can impact  surface finish.

As technology advances, so do the market expectations for higher quality products. Offering competitive pricing is a given. To meet this challenge, Intrex has made significant investments in full 5-axis and three + two axis equipment. We also have made significant investments in systems software to oversee and control our entire manufacturing process.

We would welcome an opportunity to speak to you about addressing your supply chain needs. Contact Intrex today.