How does a 5-axis CNC machine work?
5-axis CNC machining or multi-axis machining is an incredibly versatile machining process that adds two degrees of freedom to CNC machining milling or CNC machining lathes. In addition to the three axes of linear motion, the two additional degrees of freedom come from the ability to rotate the workpiece, the tool head, or both. This introduces the A, B, C axes that rotate around X, Y, Z, respectively.
The additional degrees of freedom allow for greater tool accessibility, enabling the machining of more complex geometries. There is also the added benefit of single-setup machining, sometimes referred to as an "all-in-one", which increases efficiency by reducing machining time.
There are 3 main types of multi-axis CNC machines: 5-axis indexing CNC machining milling, 5-axis continuous CNC machining milling, and 5-axis milling/turning machining centers.
What is 5-axis indexing CNC milling?
5-axis CNC machining milling or 3+2CNC machining, which works by rotating the workpiece around the B-axis and C-axis to the desired position. The workpiece then remains stationary while the cutter makes the desired cut around its three linear axes. When you change the cutting position, the B- and C-axes reorient the workpiece and then remain stationary again at that cutting position. This machining method is also known as 3+2CNC machining milling because the extra two degrees of freedom cannot work simultaneously with the three linear axes of the tool.
The main advantage of this method is that there is no need to manually reposition the workpiece. This reduces manufacturing time and improves the accuracy of parts with complex geometries compared to using 3-axis milling.
What is 5-Axis CNC Machining Milling?
Five-axis CNC machining is similar to a five-axis indexing CNC milling machine, but the workpiece can be continuously rotated around the B-axis and C-axis during CNC machining. Between them, the workpiece and tool can move along five different axes at the same time, enabling the machining of complex features. Smooth, contoured surfaces, such as those on turbine blades, can be produced with very high precision, making this method popular in the aerospace industry. The combination of expensive machinery and the need for high-level mechanics significantly increases the cost of this method.
Turn-milling compound machining center, as the name suggests, is a combination of CNC milling machine and CNC lathe. The workpiece can be rotated at high speed on the axis of rotation for CNC machining turning operations, and then rotated and held at a precise angle for CNC machining milling operations.
5-axis CNC machining is suitable for more complex parts; Since only one setting is required, higher part accuracy and production speed can be achieved. Ability to machine complex features and smooth surfaces in a single setup, producing complex parts with a level of precision unattainable by any other process
5-axis CNC machining is best suited for parts that require a smooth, contoured surface
If the part has certain features of rotational symmetry, a mill-turn CNC machine can manufacture the part at a lower cost than other 5-axis machines.
The most commonly used cutting tools are flat end mills
This tool is used for roughing and cutting 2D features, such as carving into parts.
Bullnose end mill:
A flat-bottom cutter with rounded edges makes this tool suitable for machining cavities that require a radius at the bottom of the wall. This tool is usually used for roughing, as the corner radius is less prone to breakage.
Ball nose end mills:
Spherical tools have hemispherical ends, making them ideal for machining high-quality 3D contoured surfaces.
Roughing end mills:
This type of end mill has serrated teeth, so the cutter can quickly remove a large amount of material. This tool has a lower cutting accuracy than a standard end mill and leaves a rough finish on the part
Face mill:
This circular cutter has a flat head with multiple carbide cutters and is usually used to create a flat surface on the workpiece at the beginning of the machining process. Multiple knives mean fast material removal while leaving an ultra-clean surface.
Drill bits and reamers:
Drill bits are the most cost-effective way to machine round holes in a workpiece. For non-standard hole sizes, the reamer tool can be used to expand the hole to very specific dimensions and tolerances.
Taps and thread mills:
Taps are the most common tool for creating threads, however, for CNC machines, thread milling cutters can be used to cut internal or external threads. Thread milling cutters are more suitable for hard materials that are difficult to penetrate with tapping tools
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