High Precision, Higher Quality 5 Axis CNC Machining Services

What is 5-Axis CNC Machining?

5-axis CNC machining is well-known in the modern part manufacturing world because of its incredible advantages and ability to achieve precision.

It is an extremely productive manufacturing technique that helps to machine complex parts rapidly.

It is a great approach to produce parts with complex geometries.

5-axis CNC machining features high technology that also makes it a bit expensive and difficult to operate.

Most importantly, it enables the manufacturers to machine extremely intricate parts, and that makes it perfect for the aerospace industry.

5-axis machining comes in the following variants:

• 5-axis indexed CNC milling
• Continuous 5-axis CNC milling
• Mill-turning centers with live tooling

These advanced systems are lathes or milling machines that are enhanced with additional degrees of freedom.

Indexed 5-axis CNC milling

It is also known as 3_2 CNC milling machines, and they eliminate the need for manual repositioning of the workpiece.

These machines handle the parts perfectly and can machine them at higher accuracy in regards to any other CNC technology.

Continuous 5-axis CNC milling

The machine architecture of these systems is similar to the indexed 5-axis CNC milling machines.

During all the machining operations, it allows the movement of all five axes at the same time.

Mill-turning CNC centers

CNC lathe machines equipped with CNC milling tools together make a perfect system that offers high productivity and geometric flexibility and is known as mill-tuning CNC centers.

Additionally, 5-axis CNC machining makes it possible to machine parts featuring ‘organic’ geometries.

What are the Benefits of 5-Axis CNC?

5-axis CNC machining with an effective manufacturing process offers infinite possibilities.

The use of 5-axis technology raises the limit on the types of part geometries that can be machined.

Producing highly complex parts in a single setup is the primary benefit of this advanced machining technology.

5-axis CNC machining redefines your overall capabilities and unbridles the imaginations of your engineers.

It helps in the cost-effective manufacturing of your parts and offers the following advantages:

• Complex Designs: Its ability to machine parts with complex shapes and designs enables it to machine the parts in a single process by eliminating the need to create complex fixtures.
• Rotational Accuracy: 5-axis CNC enables you to achieve superior quality by allowing you to machine multiple and complex shapes in a single setup without losing precision to maintain quality and performance.
• Minimized Setup: Sometimes, parts that require machining on several faces need multiple machining setups. 5-axis CNC technology completes the job in a single setup in a cost-effective manner.
• Fast Material Removal: 5-axis CNC machining is rapid allows for low cycle times that also save costs.
• Better Surface Finishes: 5-axis CNC technology eliminates the vibrations at extremely high cutting speeds that help achieve a better surface finish, leading to longer lead times.

There are also some secondary advantages of 5-axis CNC machining, including:

• Ability to produce more complex shapes
• Reduce re-fixturing
• Reduced labor cost-per-part
• Feature-to-feature accuracy
• Faster cutting speeds
• Increased opportunities in major markets

The use of 5-axis CNC machining services leads to increased productivity. Many technologically-enhanced industries admire its ability to use shorter cutting tools for higher cutting speeds.

What is the Difference Between 5-Axis and 3+2 Axis Machining?

In general, 5-axis machining helps you achieve tighter tolerances of parts featuring complex geometries.

While 3+2 axis machining allows you to hold fewer complex parts in certain positions, it allows better access to features.

5-axis machining features a continuous adjustment of the cutting tool along all its axes.

In this way, it can maintain a top optimal perpendicular to the workpiece.

On the other hand, 3+2 axis machining works on the same principle as 3-axis machining with the addition of a cutting tool locked at an angle determined by the two additional axes (rotational axes).

The primary advantage of 5-axis and 3+2 axis machining is speed.

However, it is possible to produce the same results with both machining techniques. 3+2 axis machining can be achieved by adding a tilt-rotary trunnion or a rotary table to a vertical machine.

The workpiece remains stationary in 3+2 axis machining and allows its processing from all sides.

With 5-axis CNC machining, the tool and the part both remain in a constant motion to maintain a continuous contact that leads to precision machining of your parts.

What are the Strategies of 5-Axis CNC Machining?

The applications and advanced processes of 5-axis CNC machining are on the rise as technology changes.

Ultimately, your production targets determine the CNC machining services you choose.

The right manufacturer can choose the right machining strategy to fulfill your expectations and select the right CNC technology to deliver the best results.

The following are some of the strategies to get the most from 5-axis CNC machining:

Collect information

It’s essential to understand the advantages of both 5-axis and 3-axis machining to get the right technology for your parts machining.

Studying the part design can give you precise knowledge about the accuracy, precision, and technology required to process your order in a cost-effective way.

Creative workholding

The optimized machining facility with optimized equipment can eliminates setups and reduce handling and can leads to higher productivity without compromising on time, cost, and your part’s quality.

Simulation software

Before sending your parts to a CAD system, it’s essential to run simulation software to avoid collisions. Sometimes, it’s hard to visualize the collision points when working on a 5-axis CNC machine.

Moreover, the simulation software allows you to precisely monitor the length and interference of the tool and the size of your parts.

Tooling

5-axis CNC machining tools can serve high-speed applications and leads to perfect part machining without requiring any use of manual force.

Run kinetics

Run kinetics can help you improve your part’s accuracy.

It’s always recommended by the professionals to run the kinetics in order to understand the part’s processing and improving it to achieve precision.

What Materials Can be Machined in 5-Axis CNC?

When it comes to materials, 5-axis CNC is more capable than any other traditional machining technique.

It supports all standard and non-standard materials with regards to correct speeds and feeds, along with the proper tooling.

Like every other manufacturing technology, 5-axis CNC also has some size and thickness limitations of some materials.

With a vast library of options for materials, techniques, and customizations, 5-axis CNC machining successfully machine parts for many crucial industries and revolutionized them.

The following are some of the primary materials that can be machined in 5-axis CNC:

• Stainless steel
• High Purity Aluminum
• Copper
• Brass
• Titanium alloy
• Inconel
• ABS
• Acrylic
• Nylon

5-axis CNC machining ability to cut down setup time enables it to speed up the manufacturing process of your parts.

Moreover, it permits the designers to consider complex designs and superior materials that were previously impossible or uneconomical to produce.

What are the Applications of 5-Axis CNC Machining?

5-axis CNC machining is ideal for a vast library of applications thanks to its faster drilling, reduced labor, higher cutting speeds, and better surface finish.

It benefits from employing five axes simultaneously and becomes incredibly versatile.

The reason behind the incredible success of 5-axis CNC machining is its enhanced capabilities and applications that are more diverse than any typical 3-axis machining.

5-axis CNC machining can be extremely productive, and manufacturers can take benefit from its freedom of movement to serve many major industries.

Aerospace industry

The limited amount of re-fixturing required by 5-axis CNC machining is one of the reasons why it’s ideal for the aerospace industry. It is the perfect manufacturing technique that handles the complexity of typical aerospace components.

Automotive industry

It’s characterized by high production volumes with a critical consistency. The automotive industry became an ideal application of 5-axis machining due to its fast techniques and advance, highly accurate tooling.

Medical industry

The parts related to this industry have extremely stringent requirements. 5-axis CNC machining is required to machine implants, medical impellers, and CT scanner components.

Energy industry

It’s the backbone of all other industries, and it encompasses many different technologies. It requires a machining system that can reliably produce advanced components that feature complex geometries, and 5-axis CNC machining is ideal for this fulfilling this purpose.

Industrial sector

It includes many other industries, including:

• Manufacturing of consumer products
• Mining
• Construction
• Marine & Oil/Gas engineering
• Ministry of defense

At least for now, no other manufacturing technology is capable of matching the pace and flexibility of 5-axis CNC machining.

What are the Features of 5-Axis CNC?

5-axis CNC machining has featured high efficiency and precision.

It’s a high-tech method with the ability to process parts with complex shapes by maintaining the optimal cutting and improving the cutting conditions.

The following are some features of 5-axis CNC that help to reduce the processing time, improve machining precision, and to achieve high production efficiency.

Optimal tool paths

A quality CAD system is critical for 5-axis machining. It determines and approximates the required tool path with a sequence of points.

Simplified programming

The following features of 5-axis CNC machining allow you to make the part’s programming independent and eliminate any complex math from post-processes:

• Workpiece setting error compensation
• Tool center point

Advanced algorithms

5-axis CNC machining features like AI contour control and smooth tolerance control help enhance the advanced real-time spline look ahead algorithms.

It helps to produce more accurate parts with a better surface finish in a shorter cycle time.

Process specific profiles

It is an easy setting function of 5-axis CNC machining. It allows us to define process-specific dynamic profiles for the tool path.

Doing so can lead to the optimal performance profile of the machine for roughing, general, or finish processes.

These features are critical to optimizing the 5-axis machining performance.

These machines with the latest technology and enhanced functionality can significantly reduce overall part manufacturing time and lead to a more efficient machining process.

What are the Types of 5-Axis CNC Machining?

5-axis CNC machining offers the strongest cutting ability in its class.

There are different types of center designs of 5-axis CNC machining, including:

• Simultaneous 5-axis machining with tilting/swivel spindle
• 5-axis machining centers with rotary and trunnion table
• 5-face machining with single/multi-axis head

Moreover, several configurations and types of 5-axis CNC machining help meeting the requirements of advanced industries, including:

Head/Head

In this type of CNC machining, the rotary axes of the 5-axis machine are situated in the head.

It keeps the workpiece in place through a fixed table. However, it offers limited movements in the rotary axes and tilt, resulting from its design.

Table/Head

In this type of machining, the two rotary axes of 5-axis machines are simultaneously located in the machine’s table and head.

The rotary shaft that is located on the table has no range limitations. However, the revolving axis in the machine’s head has a restricted range.

Table/Table

In this type of 5-axis CNC machining, two rotary axes are located inside the table. Both axes have a restricted range and scope in the revolving axis.

What is the Difference Between 5-Axis and 5-Sided CNC Machining?

5-axis CNC machining is a lot different from 5-sided machining.

However, it is possible for people to mistaken 5-axis machining for 5-sided machining.

The primary difference between both is that the 5-axis machining has five axes of x, y, z, a, and b (or c). The x, y, z, and a, c axes form a 5-axis linkage machining.

It is suitable for the following tasks:

• Hook surface machining
• Unusual shape machining
• Hollow machining
• Punching
• Oblique cutting

On the other hand, 5-sided machining is similar to 3-axis CNC machining.

It can process five sides but cannot do special machining like oblique holes or cutting bevels.

What are the Limitations of the 5-Axis CNC?

While the 5-axis CNC machining is excellent in terms of speed, precision, and accuracy, it also has some limitations.

In the manufacturing and production industry, 5-axis machining has great importance and many advantages.

The primary technical requirements for CNC machines are the following, and 5-axis CNC machining fulfills each one:

• Multi-axis
• High speed
• Good rigidity
• High power

But it also limits us in the following ways:

• The cost is too high
• Complex and difficult programming
• High technical requirements
• Tooling solutions are expensive

However, it is extremely complicated when it comes to designing and machining parts with complex geometries.

How 5-Axis CNC Machining Maintains Optimal Cutting?

In order to maintain the optimum cutting conditions in 5-axis CNC machining, it’s important to rotate the table.

Moreover, handling irregular parts in the best cutting conditions also requires multiple times rotation of the table in different directions.

By avoiding the centerline speed of the ball cutter, it can be seen that the 5-axis CNC machining can achieve better surface quality.

How 5-Axis Machining Reduces Processing Time?

Compared to any other advanced machining technique, 5-axis CNC helps to reduce the processing time of parts.

Because of its incredible features and single setup, it manages to machine parts faster and effectively.

Increasing machining efficiency leads to reduced processing time that accelerates your end products to the market faster.

The cutter plays an important part in reducing the processing time by maintaining a vertical condition of the complex mold procession surface in 5-axis CNC machining.

The principles of 5-axis machining also help eliminate the rib-like lines cause by the ball cutter due to side milling with an angled surface.

This reduces the manual work that needs to clean the mold surface and makes the surface quality of the mold more ideal.

How 5-Axis CNC Improves Machining Precision?

The 5-axis CNC machining requirement of minimal setups increases its accuracy and machining precision.

It helps to increase the longevity of a particular tool that indirectly affects the cost of your parts machining.

Many times, the problem of repositioning the part at a complex angle inaccuracy has been solved through 5-axis CNC machining technology.

Utilizing it not only reduces the machining time but also improves the machining tolerance.

In this way, it enables us to process complex parts, such as taper machining, drilling, cavity crypts for complex surfaces, etc.

How 5-Axis CNC Helps Achieving Quality Surface Finishing for My Complex Parts?

The configuration of 5-axis CNC machining helps create the part’s surfaces with a quality finish.

Due to the fact that parts are held very close to the cutting tools in 5-axis CBC machining, it leads to a quality surface finish by eliminating the vibration due to part processing.

The extra movements in this configuration give room for manufacturing angles and arcs that also help cut the intricate shapes.

How 5-Axis CNC Machining Helps Improve My Business Productivity?

By reducing the auxiliary and machining time of the parts, 5-axis CNC machining increases your business productivity.

Its powerful large cutting capacity is the reason behind its large feeds range and spindle speed.

In the era of high-speed machining, 5-axis CNC holds a special place.

The incredible positioning and rapid movement of 5-axis CNC machining led to reduced turnaround time and improved production efficiency and machining precision.

What Parts Can 5-Axis CNC Machine?

5-axis CNC machining helps you unlock the complexity and precision for all your machining needs.

It enables you by offering precision machining for complex and time-sensitive parts with unparalleled flexibility and speed.

It is widely used in the automotive industry in the prototyping and production of components, including:

• Engine housing
• Engine covers
• Valves
• Inspection jigs
• Light guides

Moreover, its ability to perfectly handling part’s complexity is the reason behind its use in the aerospace industry.

Aircraft components like the following that features intricate geometries require 5-axis CNC machining:

• Bulkheads
• Fuselage sections
• Landing gear components

Surgical tools are frequently fabricated with 5-axis CNC machining because of their high level of precision and large quantities requirement.

Medical tools that require 5-axis machining are the following:

• Scalpels
• Forceps
• Cutters
• Spacers
• Clamps
• Surgical scissors

5-axis CNC machining is also employed by governments for military projects o machine complex parts, including:

• Turbine blades
• Submarine parts
• Engine parts
• Sensors
• Weapons

The efficiency and deftness of 5-axis machining enable the fabrication of heat sinks and essential parts for consumer electronic devices such as digital cameras and laptops.

It is also useful to cut deep mold cavities with minimal shatter and maximum precision.

What is the Difference Between 5-Axis CNC Machining and 3D Printing?

It’s a hot topic in the manufacturing world right now, especially because of the incredible advantages these both part manufacturing techniques have to offer.

Both of these manufacturing techniques are compatible with a wide variety of materials, including both metals and plastics.

The drawback of 3D printing is that it is more focused on plastics.

Most importantly, 5-axis CNC machining offers more accuracy by achieving tolerances of +/-0.01mm.

However, both have size limitations and geometric complexity, but 5-axis CNC machining is considered fast and cost-effective.

How Does 5-Axis CNC Machining Works?

The best way to understand how 5-axis CNC machining works is to focus on is its features and linear motion capabilities.

In regards to 3-axis machining, it has two additional axes that offer rotary motion.

All axes (three linear axes and two rotary axes) of 5-axis CNC machines enable the cutting tool to access the parts from all angles.

5-axis CNC machining offers enhanced flexibility and efficiency to machining processes with fewer setups required.

Moreover, it is more efficient by offering you the ability to process your complete orders in a single run.

Why Choose 5-Axis CNC Over Other Machining Techniques?

The ability of 5-axis CNC machining to machine incredibly complex parts in a fraction of the time helps it conquered the manufacturing world.

This precision engineering process increases your business productivity by machining parts in a single setup that leads to reduced lead time.

Moreover, it produces precision results by offering a superior level of accuracy.

5-axis CNC machining is popular for industries where quality and part performance is critical.

It acts as an industrial-leading precision engineering process by maintaining the optimum cutting position.

What are the Advanced 5-Axis CNC Technologies?

5-axis CNC machines are equipped with a multifaceted machining center and gantry processing center that helps them meet your dynamic requirements in extremely versatile manners.

Industries where machining requirements are complex, require 5-axis CNC machining services.

It replaced the traditional milling machines and cutting tools by performing tasks accurately by maintaining precision.

The technologically-enhanced electro spindles define the creative technology behind 5-axis CNC machines.

5-axis CNC machines are manufactured to high tolerances that allow manufacturers to process different materials like resin, compound, aluminum, and many others to be machined.

Why Choose DEK?

At DEK, our state-of-the-art 5-axis CNC equipment offers a wide variety of capabilities.

Perform machining quickly and accurately shortens cycle times and improves the quality of the machined surface.

Our extensive knowledge enables you to benefit from our commitments to risk management, safety and quality standards, and industry regulations.

Our 10+ years of experience and skilled staff design and develop parts as well as machine them.

We pay attention to aspects of efficiency, safety, and situational durability when machining your parts.

In order to discuss our precision engineering capabilities and your project plans, you can get in touch with us.

Our friendly and highly experienced staff will be more than happy to assist you.