What is 5-Axis Machining: Definition, Types, Benefits & Applications

Machining processes are widely used to manufacture components for different industries. When it comes to considering CNC machining for projects, there could be various options, and among them, 5-axis machining is also commonly adopted.

The 5-axis machining process helps to manufacture components that are equipped with excellent precision and complex shape. If you want to learn what is 5-axis machining, its types, and its benefits, read the guide below.

What is 5 Axis Machining?

5-axis machining is a process of machining that removes material from the workpiece. It has five axes to work on; the three linear axes are X, Y, and Z, and also A and B, which are the rotational axes. Hence, at the same time, the tools can approach the workpiece in 5 different directions and cut it in a single operation, offering highly precise results.

Why Use CNC for 5-Axis Machining?

5-axis machining offers ample benefits. It has multiple axes and can be cut from different sides with great flexibility. Many industries require components that are complex in shape and have intricate details, and 5-axis machining works well in these cases.

This process of 5-axis machining doesn't have any design limitations, as the cutter tools can approach the component from any angle without changing its position. This improves the overall machining quality and consistency of the part, especially in deep, narrow grooves and hard-to-reach spaces. Hence, the process helps to manufacture components quickly and may allow them to float in the markets in less time.

How Does A 5 Axis CNC Machine Work?

A 5-axis machine can work in an automated way with no human intervention. It consists of using tools that even rotate, and hence, the materials can be cut in desired shapes.  The workpiece is placed on the machine, and the design is created in the CAD software, which translates it into the CAM so that the machine can understand the G-code.

The G-code instructs the machine to make the required movement based on the design and derives its tool path. The machine cuts the components, and the desired component is achieved.

Types of 5-Axis CNC Machines

There are different types of 5-axis CNC machines, and these are as follows:

Head/Head

Head/Head CNC machining is where the head comprises the rotary axis. The machining is carried out on a particular platform. There is no interference as the 5-axis moves over a fixed table; hence, the workpiece also remains fixed. These machines are suitable for machining larger components.

Table/Head

The table/head has one rotary axis on the head and one on the rotary table. The revolving axis of this machine lies in the head, and the parts revolve throughout the process of machining.

Table/Table

This setup has the rotary axis on the table, and the rotary axis rotates on the table. It is suitable for machining undercuts. This process is slower than the other types of machining processes and can work with parts of small size.

Benefits of 5-Axis CNC Machining

The process of 5-axis CNC machining comprises multiple advantages, and some of these are as follows:

• The 5-axis CNC machines have an additional axis, which makes the process of machining very quick and easy and is also suitable for complex shapes.
• Compared to manual processes of machining, it is very quick, and due to the lack of human intervention, the chances of errors are minimal.
• The setup of 5-axis CNC machining is very easy. The machine can work on the 5-axis in one go, making the process very quick and capable of achieving the desired geometry.
• The surface finish of the components manufactured through the 5-axis CNC machining is quite smooth because the tools work on the components very closely to achieve the required shape.
• 5-axis machining is a suitable process for all types of components irrespective of their sizes due to its versatility.

Drawbacks of 5-Axis CNC Machining

The process of 5-axis machining has some downsides as well, which are as follows:

• The investment in the 5-axis CNC machine is very high compared to the other CNC machines. Moreover, the cost of maintenance of these machines is also quite significant.
• The process of programming the 5-axis machine is also complex, whereas the 3-axis machines are easy to program. Hence, an expert machinist is required to program them.
• The skills of operators need to be excellent for operating the 5-axis machine as they have highly advanced technology involved.

What Kind of Parts Can Be Machined Using a 5-axis Machining Center?

There are different types of parts that can be machined using 5-axis machining, and some of these are as follows:

• Complex surface components that are used in aerospace, electronics, and aviation are manufactured using 5-axis machining, like blades of turbine engines, spherical surface impellers, etc.
• 5-axis CNC machining is a process that can help manufacture disc parts that have radial holes. It also helps to manufacture motor covers.
• The process of machining box-shaped parts is difficult using other machining methods due to the alignment and clamping requirements. 5-axis CNC machining helps to manufacture such parts with high precision.
• The parts that have special shapes with mixed points, lines, and surfaces are also the ones that are machined using 5-axis CNC machining because it cuts the component very closely.

5-Axis Machining vs. 3+2 Axis Machining

When it comes to comparing the 5-axis machining with the 3+2 machining, there are some major differences. The basic difference is the number of axes; the 5-axis machining has a cutting tool that works in the five-axis and even rotates. Whereas 3+2 axis machining is a 3-axis program and a cutting tool that is locked at a given angle, the lock angle depends on two axes that rotate.

5-axis machining is very fast, whereas the 3+2-axis machining is a bit slow. 5-axis machining is a continuous process with no stops in between.

Practical Tips for Using 5-axis CNC

When it comes to 5-axis CNC machining some of the important tips to follow so that you achieve optimum results.

• When you choose 5-axis CNC machining, always learn about the software and controls. It helps you achieve components that are well-designed.
• The tool selection is very important to ensure seamless design and the right tool even helps to minimize the chances of errors. You can use a tool detection system that helps you analyze and choose the right tool.
• Collisions can lead to defects in components, and some software helps mitigate these collisions.

Applications of 5-axis CNC machining

The applications of 5-axis machining are observed in various industries, and some of these are as follows:

Medical

Medicine is one of the most sensitive fields, where it is important to have the right machined tools. 5-axis CNC machining offers high precision. Accuracy and hence the components like medical tools, surgical implants, and other orthotic tools are manufactured using 5-axis machining.

Electronic

Electronic devices are used in everyday life in many applications, and 5-axis CNC machining helps to manufacture components used in these devices. It is composed of electronic housing, hardware, heat sinks, and semiconductors.

Energy Sector

The energy sector requires components that are equipped with accurate specifications and dimensions. Hence, 5-axis CNC machining helps create these components. Most of the parts used in the energy sector are cylinders, pistons, bits, and rods.

Aerospace

The aerospace industry needs components that have contoured edges and complex shapes, which can only be achieved through 5-axis CNC machining. This process helps to manufacture high-quality aircraft components that suit the sensitive needs of the industry.

Start Your 5-Axis Machining Project at DEK

5-axis CNC machining services at DEK can offer you complex components made with the finest accuracy and precision. We have been in the field for years, and our team can offer expertise in manufacturing these components with seamless finish. So, get in touch with DEK for your projects.

Conclusion

Learning about 5-axis machining is very important before you start the project, and the guide must have given you an insight into it. The processes involved, their pros and cons, and applications everything requires understanding so that you can make informed decisions when incorporating them into your projects.

FAQs

What materials are used in 5-axis CNC machining?

5-axis CNC machining is a versatile process that can work with all types of metals and plastics. It is even compatible with composites.

How much does five-axis CNC machining cost?

5-axis CNC machining is expensive compared to other machining processes and the price varies based on the nature, size, and material used for the component.

What language do 5-axis CNC machines use?

The 5-axis CNC machines use a G-code for the purpose of machining.

What is the difference between 3 and 5-axis CNC machining?

5-axis CNC machines have 5- axes, which are composed of 3 linear and 3 rotational; 3-axis CNC machining has 3 linear axes to work on.

What are the five forms of 5-axis machining?

The five forms of 5-axis machining comprise the x,y, and z axes, which are linear movements, and the A and B axes, which are rotational movements along the x,y, and z axes.

Why is there less fixturing with five-axis CNC machining?

The machine can approach the component from different angles; hence, there is less fixturing.