The benefits of 5 axis machining may not be obvious to non-experts. After all, your CNC machined parts are three-dimensional, not five-dimensional, right? Intuitively, you might think that a 3 axis CNC machine should be capable of handling most machining jobs.
In actual fact, 5 axis machining is today the most viable solution for all kinds of machining projects — not just highly complex ones that demand greater tool reach.
In the manufacturing field, custom CNC machining services are one of the most important ones. It is the procedure of eliminating material with high-speed precision machines by using different cutting tools. It offers different techniques to produce products and you can choose the best method according to your next project’s need.
For newcomers to CNC technology, 5 axis CNC machining is a form of CNC machining in which the workpiece (the part in progress) or the cutting tool can move along five axes.
In many cases, it’s a combination of the two — for example, the cutting tool moves along three axes (up and down, back and forth, side to side) while the table holding the workpiece moves along two (rocking back and forth, rocking side to side).
5-axis CNC machining is highly used when it comes to the most complicated and requires high precision. You can expect a much higher accuracy from this method of manufacturing.
There are different advantages you can obtain from 5-axis custom machining services. This article will discuss all those pros of this method and you just need to delve into it to thoroughly understand them.
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.
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.
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.
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.
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.
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.
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.
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.
Here another most important thing to consider is to hire a professional manufacturing company that can help you to achieve your exact needs and specifications for your next projects. As money and time are precious and you need to spend them appropriately, make sure you are in the right place. Hence, here we will share some basic tips regarding this purpose to make this process easier for you.
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.
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.
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.
Hiring a reliable 5-axis Machining service
Make sure your manufacturing team has been in operation for a considerable length of time. They ought to be highly experienced and skilled that will ensure the quality of work and the turnaround. A company should be reliable and trustworthy.
Do not hesitate to ask some questions about the 5-axis machining that a company has before deciding on them. A machine also has to be of higher quality and able to complete this job within a deadline.
Ask them about the cost of their services. Make sure you pay for what you are getting and it should match the product quality. Also, aware of the materials that they will be using.
Proto MFG is a leading manufacturing company providing custom 5-axis machining services.