11 Benefits of 5-Axis CNC Machining
For the non-expert, the benefits of 5-axis machining may not be obvious. After all, your CNC machined parts are three dimensional, not five, right? Intuitively, you might think that a 3-Axis CNC machine should be able to handle most machining jobs.
In fact, 5-Axis machining is the most viable solution for a wide range of machining projects today, not just highly complex projects that require a larger range of tools.
Custom CNC machining services are one of the most important services in the manufacturing sector. It is the process of eliminating materials using high speed precision machines with different cutting tools. It offers different techniques to produce products and you can choose the best method according to the needs of your next project.
For those new to CNC technology, 5-axis CNC machining is a form of CNC machining in which either the workpiece (the part being machined) or the cutting tool can be moved along five axes.
In many cases, it is a combination of the two – for example, the cutting tool moves along three axes (up and down, back and forth, left and right), while the table holding the workpiece moves along two axes (back and forth, swing) side to side).
5-axis CNC machining is heavily utilized when it comes to the most complex and high precision requirements. You can expect a higher level of precision from this manufacturing method.
There are different advantages that you can get from 5-axis customized machining services. In this article, we will discuss all the advantages of this method and you just need to dig deeper to understand them thoroughly.
Accurate and Affordable Parts
If you need the most complex parts done in one step, then you must consider 5-axis machining, which also reduces machining time, errors and tooling costs. It ensures faster, accurate and affordable results for your next project. You get precise accuracy without compromising the precision needed to maintain quality. Reduce cycle times by eliminating more material with each tool pass.
Complex Designs
5-axis machining offers a range of advantages over 3- or 4-axis options, including the ability to create complex parts. This is a key reason for the growing popularity of 5-Axis machining in modern manufacturing.
The ability to assist with complex CNC machining can be realized through the greater range of motion and positioning of the cutting tool provided by 5 Axis machines. This increased flexibility allows for greater precision and accuracy, resulting in more complex designs that would be challenging or impossible to create using traditional manufacturing methods.
Additionally, 5-Axis machining eliminates the need for multiple machines to create complex parts, saving time and cost during the manufacturing process. For companies adopting 5-Axis machining technology, this reduces turnaround time, increases efficiency and improves competitiveness.
Higher speed 5-Axis machining allows shorter cutting tools to be used, given that the head can be lowered and the tool can be oriented to the surface. You get higher cutting speeds and tool vibration with optimal results.
Setups are reduced with 5-axis machining; you can work on different surfaces at the same time. Often, in other technologies, you need to do multiple setups to get complex geometries with manual rotation. However, 5-Axis machining takes all this pressure off. This advanced method is sufficient to handle extremely complex solid parts. For different materials, it can also handle a wide range of raw materials, including tool steel, carbon steel, sterling silver, brass, stainless steel, bronze, and other high-temperature alloys.
Save time
This cutting-edge machining solution saves you time when drilling holes, which can be time-consuming when using compound angles. With 5-axis machining, positioning the head along the right axis of each hole is simple.
Increased productivity
One of the most time-consuming aspects of 3-axis machining is setting up the workpiece multiple times, as the part needs to be reoriented. This is necessary if all or more sides of the part need to be machined, as the cutting tool remains at a fixed angle. For these 3-axis operations, the machinist must be physically present to reorient the part after one side is machined, and this labor requirement can be a serious bottleneck to productivity.
5-axis machining greatly reduces the need for multiple setups because table or spindle movement allows the cutting tool to approach the part from different angles without having to remove it from the machine and reset it. This increases the productivity of the entire process.
By utilizing 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 organizations looking to increase efficiency and throughput while maintaining the highest standards of accuracy and quality.
Shorter cutting tools and higher quality
A serious disadvantage of 3-axis machining is the need for long cutting tools due to limited movement.
5-axis machining allows the use of shorter cutting tools because the machine allows the tool to approach the workpiece at a better angle. This has important knock-on effects, such as allowing faster cutting speeds without the risk of damaging the cutting tool or increasing unwanted tool chatter, which affects the quality of the part and the ability of the machine to achieve tight tolerances.
Using shorter cutting tools benefits both the machine shop and the customer. The machine shop has a longer life expectancy for its cutting tools, while the customer receives better part quality and surface finish and can demand tighter tolerances on fine features.
Superior Surface Finish
The last 2 axes will help you position the part and bring it closer to the cutting tool. This allows you to use shorter cutting tools and get a better surface finish.
The other most important thing to consider here is hiring a professional fabrication company that can help you realize the exact needs and specifications of your next project. Since money and time are precious and you need to use them properly, make sure you are at the right place. Therefore, we are here to share some essential tips for this purpose to make the process easier for you.
Easily and accurately cut mold cavities
5-Axis machining produces higher quality molds because the increased degree of motion allows for better handling of deep cavities compared to 3-Axis machining. 5-Axis’ increased precision also improves the surface finish of the mold, reducing the need for full polishing.
Simultaneous 5-axis machining is also ideal for high core molds and deep cavity molds.
Reduced labor costs
Optimizing the production process can bring a number of benefits to a company, including reduced labor costs. In the context of 5-Axis CNC machining, two key factors contributing to this outcome are faster operations and the elimination of multiple setups.
By reducing the time it takes to complete a job, faster operations can lead to a corresponding reduction in the amount of labor time required. This can result in significant cost savings for organizations, especially for jobs that require the machining of a large number of parts or assemblies.
Eliminating the need for multiple setups can also help reduce labor costs by streamlining the process and reducing the number of steps required to complete a job. By streamlining the process, companies can minimize the need for specialized labor and focus on improving operational efficiency.
The benefits of reducing 5 Axis CNC machining labor costs go beyond immediate cost savings, as they also free up resources for investment in other areas of the business. This can enable companies to reinvest in R&D, expand operations or allocate resources to other areas that will help drive long-term growth and success.
Perfectly Bent Parts
Curved parts such as fins and turbine blades are not suitable for 3-axis machining, much less alternative processes such as FDM 3D printing, which is notorious for its stepped surface finish.
On the other hand, with simultaneous 5-axis machining, it is possible to machine smooth and consistent curves on a workpiece, or to machine details on an already curved workpiece.
By rotating the table or spindle as the tool cuts the workpiece, a consistent cutting angle can be maintained even along curved edges.
Hire reliable 5-axis machining services
Make sure your fabrication team has been in operation for a considerable amount of time. They should be experienced and skilled to ensure quality work and turnaround. A company should be reliable and trustworthy.
Do not hesitate to ask some questions about the company’s 5 axis machining before making a decision. The machine must also be of higher quality and be able to do the job within the deadline.
Ask about the cost of their services. Make sure that the cost you pay matches the quality of the product you get. Also, find out the materials that they will be using.
