5 Axis Machining for Defense
CNC machine tools are used for machining (metal removal) for the defense market. CNC machines are well-suited to meet the demands of the defense market, in that machined parts require tight tolerances and higher finishes. In the past the CNC equipment used to produce these parts were two-axis (lathes) and three-axis (milling). Many of the more complex shapes were produced using a combination of these machines which required multiple setups. Thanks to advances in control, servo, and tooling technology, we can now accomplish 4- and 5-axis simultaneous machining. 5 Axis machining for defense has significant advantages for creating complex machine shapes.
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 move. 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 to approach the workpiece from any direction.
Complex Shapes
The major advantage of five-axis machining is the ability to simultaneously machine complex shapes, without having to move the workpiece.. The ability for the machine in a single chucking to move in a 5-axis simultaneous mode, gives the machine the ability to create angles, arcs and chip relief that were only previously possible with a multiple fixtures and ssetups.
Improved Tool Life
Improve tool life and speed up cycle time as a result of tilting the tool/table to maintain optimum cutting position and constant chip load.
Setup Reduction
Five-axis machines can machine nearly every visible surface, excluding the bottom or clamping area. This ability significantly reduces the need for multiple setups or special fixtures. In some instances, it reduces the number of setups to one.
Improved Accuracies
Imprecision happens every time you have to “rechuck” the part. This tolerance stack-up is one of the results and challenges of moving a part for re-fixture. By using the same “zero” or “home” location, feature-to-feature accuracy is improved.
3+2 Axis Machining
Not all 5-axis parts require full 5-axis simultaneous machining. Some 5-axis parts are best machined with a 3+2 movement. In 3+2 machining, the fourth and fifth axes are used to locate the work piece (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.
Five-axis machining increases uptime, decreases human error, and eliminates the need for special fixtures. For parts with features or holes on multiple faces or angles, 3+2 machining is the clear choice.
Achieving Surface Finishes
Using the rotating fourth and fifth axes, the part can be orientated to bring it closer to the cutting tool. If the part can get closer to the cutting tool, then the cutting tool can be shorter. A shorter cutting tool is less susceptible to vibration at higher cutting speeds, which directly impacts surface finish.
As technology improves, so do the markets’ expectations for higher quality products at competitive pricing. To meet this challenge, Intrex has made significant investments in multiple-axis equipment, as well as 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.
