4 Axis CNC Machining: Process & Applications
CNC machining is one of the most precise and accurate methods to manufacture components. These components can be made using different materials and used in various industries.
4 axis CNC machining is a CNC machining process that can work in 4 axes while cutting the workpiece. Learning about 4 axis CNC machining can help you with your upcoming projects, so let's read below.
What is 4 Axis CNC Machining?
4 axis CNC machining is a machining process working on multiple axes. The machines have a rotary axis followed by the x, y, and z axes. These tools move in four different directions at the same time and manufacture a highly accurate component.
The Process of 4 Axis CNC Machining
The 4 axis CNC machining works step by step, achieving the desired shape and tolerance of the components. The entire workflow of the 4 axis CNC machining is laid below.
CAD Design: The first stage involves designing the digital model of the component using CAD software.
CAM Conversion: The CAD design is converted into CAM so that it can provide a tooling path for a CNC machine's cutting tool.
Preparing Setup: The setup of the CNC machine requires mounting the workpiece and setting the machine to work on it.
Machining: The 4-axis CNC machine removes the material from the workpiece from different angles and even rotates the workpiece.
Finishing: The machining process, when completed, makes the component pass through the finishing process. It cleans the components and smoothens the surface to improve durability.
Benefits of 4 Axis CNC Machining
4 axis CNC machining comes with various benefits, and some of these are as follows:
Versatility
4-axis machining offers to manufacture components that are used in all industries. Hence, the versatility of 4 axis CNC machining is exceptional. The cost of various materials and sizes can easily be manufactured.
Enhanced Capabilities
The 4-axis CNC machine has an extra axis, which helps to manufacture parts with complex designs and designs that cannot be created through 3-axis CNC machining.
High Precision
4 axis CNC machining offers enhanced control over the operations of machining based on its rotary axis. These CNC machine’s components, therefore, have high precision and accuracy.
Improved Efficiency
4 axis CNC machining can machine through different angles in a continuous way. Hence, the need to repeatedly reposition the workpiece is not required, which tends to manufacture components in less time, offering improved efficiency.
Limitations of 4 Axis CNC Machining
Along with benefits, there are some downsides of the 4 axis CNC machining, and these are as follows:
- The setup of 4 axis CNC machining is expensive and requires a high investment to be made. This investment is justified when you have to manufacture a large volume of components in the long run.
- Operating these 4-axis CNC machines requires skilled operators who can set the program and supervise the entire process. This leads to an increase in the cost of operation.
Machines Used in 4-Axis Machining
There are different types of 4-axis CNC machines that perform different machining tasks, and some of these are the following:
4-Axis CNC Lathes
4-axis CNC lathes are suitable for turning operations as the lathe allows additional tools to reach the workpiece from any angle.
Hence, a complex design can be created using different materials. A lathe is compatible with metals, plastics, and even wood and can cater to a wide range of industries.
4-Axis CNC Milling Machines
4-axis CNC milling machines are used to create intricate designs and details for the components. These may have holes and angle cuts in the complex components. The additional axis allows milling slots and holes from any required angle.
4-Axis CNC Routers
4-axis CNC routers are very commonly used in the furniture-making or woodworking industry. These machines help to work effectively on large parts. They have a very basic setup but offer durable construction.
Applications of 4-Axis Machining
The applications of 4 axis CNC machining can be seen in various industries, and some of these are as follows:
Aerospace Industry: 4 axis CNC machining offers to work on complex shapes with high repetition and hence can offer aerospace industry components like airframe and turbine parts.
Automobile Industry: In the automobile industry, complex components are needed, which require working on angles from different directions, especially body parts and engine components. 4-axis CNC machining makes this process suitable for the automobile sector.
Electronics Industry: Electronics like casings and circuit boards need higher accuracy, which is achieved through 4-axis CNC machining.
Oil and Gas Industry: The oil and gas industry needs durable parts that can be manufactured using 4-axis CNC machining so that they can withstand high temperatures.
3-Axis CNC Machining vs. 4-Axis CNC Machining
3-axis machining and 4-axis machining differ from one another in various ways, and some of these are as follows:
- 3-axis machining is a very basic machining process that performs machining in just 3-axis and cannot manufacture highly complex parts. However, 4-axis machining has four movements and can machine complex components by moving the tools in 4 directions.
- 3-axis CNC machining doesn't have any rotation axis, it just moves linearly. However, the 4-axis machine can also allow the rotation of the workplace followed by linear movements.
- 3-axis CNC machining is cost-effective because it's simple, so the cost of the machine and setup are low. At the same time, the 4-axis CNC machining cost is a little high because of the additional axis it has, which leads to high investment.
Start Your CNC Machining Project with DEK
We at DEK offer 4-axis CNC machining of components. So, if you are starting a new project and have complex components that need rotational-axis machining, you can get in touch with us.
Our years of experience and expertise allow us to manufacture custom-machined components for you.
Conclusion
Before you start your projects, it's very important to understand the details of 4-axis CNC machining.
The guide above must have provided details on it, offering you the entire understanding of the process, its pros and cons, and where it can be used.
