5-axis CNC! The machining magic of manufacturing complex parts from solid-block steel!

5-axis machining allows countless possibilities in terms of part dimension, shapes and precision requirements. We know that the term “5-axis” may be sometimes difficult to understand, so let us provide some intel on the topic.

A regular 3-axis CNC machine moves its tooling across the “X”, “Y” and “Z” linear axis. Or in other words it moves across the back/forward, left/right and up/down axis (pic.1).

On a 5-axis CNC Center the tool is able to move across the circular “A” and “B” Axis, in order to approach and process the work piece from all directions. In other words, when talking about 5-axis machining we talk about CNC that can use its tools simultaneously on 5 different axes – 3 linear and 2 rotary, and basically process from everywhere (pic.2­).

The benefits of the 5-axis centers:

• Low volume and complex geometry

Even though, many complex contours can be manufactured by 3-axis centers, there are some parts that cannot be made in a single setup without a 50-axis centers (pic3).

The addition 4^th and 5^th axis allow access to angles, arcs and undercuts, which by the conventional methods are possible only by multiple setup and set of programing.

• Rotational accuracy
  Whenever the operator sets up a part from the machine, he/she loses the exact centering of the part and this way opens a possibility for poorer accuracy. By using the 5-axis center the operator simply completes the part in a single setup and never has to bother with alignment again.
• Better surface finish and lower time consumption
  5-axes centers position their tooling closer to the work piece, which means lower distance between the tooling and the cutting surface. In other words, the center needs shorter tools, which respectively allows deeper cuts and removes more material each time it passes. Movement time is also reduced.
  Shorter cutting tools also help for better finishing, since the vibrations on the cutting area are significantly reduced.

When to use 5-axis machining?

Not all difficult to manufacture parts need 5-axiss processing. In many cases 3-axis CNCs can achieve passable results with the part. However, it often requires more programing, setup changes and program interruptions and even sometimes more manual labor. On one side this causes more labor and time costs, but on the other the initial value of the 3-axis CNC center is much lower.
Depending on the type of business and purchases that manufacturers have, 5-axis centers offer higher ROI in the long term. Short-term manufacturers of metal parts often prefer the low-cost solution.

However, when a large batch of solid parts is in demand, regardless of the complexity, the 5-axis centers offer much higher versatility, faster programing and respectively lower lead time.
It is now a coincidence that many OEM factories, Automotive and Aerospace companies, water and air turbine manufacturers prefer to rely on 5-axiss machining.

A simple example of a complex part, impossible to make with a single setup, made possible with a 5-axis CNC for our clients.