The machining industry continually adapts to market demands. There is always a demand for speed, capacity, accuracy, and a skilled workforce, as well as for reducing the involvement of human error. This is so for all industries and shop sizes. Modern technology calls for more complex parts, which is evident in several ways. New machines have been developed to address these needs, particularly 5-axis ones. 5-axis CNC machines employ the machining center's X, Y, Z, A, and B axes. This enables tools to get to a part's five sides without additional setups. To picture the 5-axis movement, hold an object in front of you. Place the tip of a pen touching the object but slightly away from it. Swing the object from side to side and up and down. Draw the pen up, down, side to side, in and out simultaneously. This demonstrates how 5-axis machines can move and work on parts. This article covers the core details of the working mechanism, pros and cons, and practical tips for maximizing the efficiency of 5-axe cnc machines.
1. How Does a 5-axis CNC Machine Work?
A 5-axis CNC machine is a CNC(Computerized Numeric Control) machine that operates based on instructions given digital instructions. As the name implies, it can move or rotate the cutting tool and the workpiece in five axes, namely in the X, Y, Z, A, and B directions. These are the three linear movements in the X, Y, and Z directions and two rotary movements in the A and B directions. The machine accurately creates the intended parts and can produce intricate structures. Additionally, the 5-axis machines are expedited with (the GD&T call-out) system for creating datum components in a single operation. Also, this technology minimizes the number of setups and excessive manual labor requirements. Regarding the axis;
● The A-axis turns typically in the X-axis direction, allowing the tool to be angled.
● The B-axis rotates around the Y-axis to enable rotations on a vertical axis of the structure.
● In complex operations, the changes in the angle can be from -120 to 120 degrees.
● The Z-axis is used in the vertical plane movements and, therefore, controls the depth.
● This makes machine-complex 3D shapes and contours possible since the workpiece can move in all directions simultaneously.
However, 5-axis machines are applied in the aerospace, automotive, and medical industries. They assist in the creation of small tolerance parts down to +/-0.005’’. There are various steps for optimally operating 5-axis cnc machines.
1.1.Design Phase
The process starts with generating a virtual 3D model of the part. Engineers and designers employ computer-aided design software such as SolidWorks or Autodesk Inventor. The 3D model replicates the intended part with all the dimensions and characteristics on an absolute scale. CAD software is also helpful in visualizing the part before the actual production of the part is made. At this stage, the designer can make corrections and adjustments to the design. High precision of the 3D model is essential for further CNC machining. The completed model is then exported to a file format that other programs can process. This model is used as a guide to the actual machining process that is to be carried out on the workpiece.
1.2.Conversion to G-Code
The 3D CAD model of the part is then transferred to CAM software. CAM software translates the 3D model into G-code. G-code is a set of instructions written in computer language that is used in machining. The code contains information on feed rate, speed, and tool path. G-code provides accurate and standard operations in machining processes. This step helps in closing the gap between the actual design and the physical implementation of the design. It is crucial to properly convert the model to G-code for the proper machining to be done on the model.
1.3. G-Code Instructions
G-code determines the motion of the cutting tool along the X, Y, and Z directions. It also controls the movement of the worktable in the A and C directions. The CNC machine then implements these instructions to the letter. Every line in G-code is associated with a particular action or motion of the machine. The code also ensures the tool is properly functioning and is not jerky. In addition, it helps develop intricate forms and characteristics. The instructions are carried out one after the other. It is vital to program G-code correctly to get the right outcome.
1.4. Machining Process
The CNC machine then begins to be machined according to the G-code fed into it. The cutting tool rotates along the planned paths to create the part. The worktable can be turned to enable access to the different sides of the part. This motion is achieved in parallel to guarantee the best results in terms of material elimination. The high precision of the machine characterizes the process throughout the process. Sensors and feedback systems supervise the machining operation. Corrections are made automatically to ensure the readings are as accurate as possible. The last part is made to precise measurements as intended by the designer.
2. How To Maximize The Effectiveness of 5-Axis CNC Machines?
Optimization of 5-axis machining is all about planning and the use of the most effective techniques. Here are key strategies to help you get the most out of your 5-axis machining operations:
2.1. Gather Comprehensive Information
Gather as much information as possible to decide between the 3-axis- and 5-axis machining. Ensure that the data given to you by your customer is accurate. Look at the part carefully to determine whether it is necessary to conduct a pretest to achieve the required level of accuracy. Carry out a cost evaluation to determine which machining techniques are cheaper. This means that proper initial planning assists in formulating the right decisions.
2.2. Utilize Simulation Software
Ensure that simulation software is optimized to check processes before moving them from the CAD system to the machine. Simulation helps determine areas of interference that are not easily imaginable in 5-axis machining. The software can accurately control tool length, interference, and part size. Such a strategy saves a lot of money that would have been spent on rectifying the mistakes and guarantees efficiency.
2.3. Innovate Workholding Techniques
Revise your workholding strategy and use methods that reduce the number of setups and handling operations. More access to all sides of the part is achieved by innovative workholding solutions, which increases production output. Modern methods improve precision and the general quality of your products. Optimizing the work-holding process can increase productivity to a large extent.
2.4. Optimize Tooling Choices
Choose tools that are made for 5-axis machining, especially for high-speed operations. The idea is to make the last step of the part as automatic as possible. Proper tools make work easier and produce quality finishes for the products being worked on. The use of special tools when carrying out machining operations can lead to a significant improvement in the results of your work.
2.5. Implement Kinetic Analysis
After this, kinetic analysis will be performed to enhance the precision of each part. This analysis assists you in determining the orientation of the ends of the cutting tool relative to the axes’ rotation points. The kinetic analysis should be done before the precision applications for better results. It helps enhance the machining process and get the desired specifications.
2.6. Embrace Technological Advancements
The advancement in technology has seen the application of 5-axis machining increase. Machining equipment is selected based on the work to be done and the production goals set. Ensure that you work hand in hand with the clients to establish their expectations and determine the most suitable machine. Updating oneself with the current technology is vital in ensuring one is relevant in the market.
Accumulating all the necessary data, using the simulation programs, developing the new approach to workholding, selecting the most appropriate tools, and calculating the kinetic parameters are the steps that should be taken. Adopting technological solutions and appreciating the client's needs help in providing quality services all the time.
3. 5-Axis Trunnion Vs. Swivel: Difference In CNC Configurations & Operation Styles
Let’s evaluate the distinctions between these two styles;
3.1. Trunnion Style:
Trunnion-style 5-axis cnc machines work with the A axis rotating around the X axis and the C axis rotating around the Z axis. This arrangement enables the machine head to be fixed while the table translates to cater to the rotary axes. It performs well in capacity and throughput, in the ability to depolarize without moving the head of the machine, and in undercutting that is required for intricate shapes of the part.
3.2. Swivel Rotate Style:
In contrast, the Swivel Rotate style entails the B-axis swiveling around the Y-axis and the C-axis swiveling around the Z-axis. During the machining process, the table remains horizontal. This setup helps machine significant parts and uses short tools to increase the machining rate.
4. Different Types Of 5-Axis CNC Machines
The 5-axis CNC machines are appropriate in processes that require speed and optimization of the operations. These machines are of many types, and the position of the rotary axes mainly determines the type.
4.1. Head/Head Configuration
In this 5-axis CNC machine type, the rotary axes are contained in the head of the machine. This design reduces the chances of the tools coming into contact with the spindle head of the machine since the 5-axis configuration is done on another table. The machining process involves the apex moving in a rotational or translational manner while the table is fixed to support the workpiece.
Head/Head CNC machines are very efficient in producing large parts because they can move about a specific item during the operation. However, this design may have limitations regarding the range along the rotary axes.
4.2. Table/Head Configuration
The Table/Head configuration, on the other hand, has rotary axes located on the head and the table. The head has one rotary axis, and because of the component position, it has minimal movement. However, the rotary axis on the table is freely rotated in any direction, which makes it easier to carry out the type of operations on the material.
The other advantage of the Table/Head setup is that there is always a circulation of parts; therefore, problems such as chatters are less likely to happen. Nevertheless, there is a limitation of the rotary axis on the table, which limits the kind of parts that can be manufactured efficiently.
These configurations aim to meet various requirements in the manufacturing sector to provide the optimal solution for the accurate and effective execution of machining tasks.
5. Advantages of 5-axis CNC Machining
5-axis CNC machining offers several advantages that make it indispensable in modern manufacturing. Here are some advantages of 5-axis CNC machining that place it among the essential technologies in the contemporary manufacturing industry:
1. Streamlined Setup and Operation: This differs from conventional machining techniques, which require multiple sets to manufacture a single part; 5-axis CNC machining can work on five faces of the workpiece simultaneously. This reduces the time taken to set up and allows the creation of complex shapes all at once.
2. Versatility in Complex Shapes: 5-axis machining has extra axes; with these axes, the machine can get to positions and planes that lesser axes cannot access. This capability is beneficial in industries where the part's geometry is very complicated.
3. Enhanced Accuracy and Consistency: Because there are a few points where manual adjustments and setups can be made, the 5-axis CNC machines will likely go right in the machining process. This leads to the generation of parts of the same quality and dimensions for the subsequent manufacturing operations.
4. Efficient Material Removal: This is because it is possible to have maximum tool utilization throughout the machining process, resulting in high cutting speeds and material removal rates. Such efficiency is reflected in such parameters as cycle time and manufacturing cost.
5. Superior Surface Finishes: Thus, because the workpiece is always well positioned about the cutting tool, 5-axis machining provides better surface finishes. This means that no other finishing processes need to be done, which cuts down on costs and time.
6. Cost-effectiveness and Productivity: 5-axis CNC machining may be expensive at the initial stages, but in the long run, it is cheaper since set-up time is eliminated, tools have longer cycle time, and little or no scrap. It also increases the total production because it can simultaneously make a part in several stages.
6. Disadvantages of 5-axis CNC Machining
Similarly, like other manufacturing techniques, 5-axis CNC machining has its advantages.
1. High Initial Investment: The initial setup is costly to acquire a 5-axis CNC machine and educate the personnel on how to use the machine. However, for other machining technologies, the hardware, software, and training costs could be higher in the initial stage.
2. Complex Programming Requirements: As observed, working on a 5-axis CNC machine means working in space dimensions and tools to be followed. Thus, it is necessary to define the space dimensions and paths of the tools. For better outcomes, one should have adequate knowledge of CAD/CAM software and the functioning of the machines.
3. Skilled Labor Requirement: However, it should be noted that the work with a 5-axis CNC machine is carried out by qualified personnel. The process of acquiring and managing competent staff may sometimes be a challenge, hence high operating costs.
4. Machine Utilization Challenges: To get the best of it, one must be very familiar with all the axes of a 5-axis CNC machine. This may result in the machine's non-provision of training or programming; therefore, the machine may be underutilized.
5. Maintenance and Service Needs: It should also be noted that due to the axes that are mounted on the 5-axis CNC machines, they may be more prone to wearing off and thus may need frequent servicing and adjustment. This is under operating expenses and time that could have been used in production if the management of the material was efficient.
6. Adaptation to Specific Applications: However, one has to note that 5-axis machining is typically effective; however, it cannot be used for all types of parts or materials. Some geometries or material properties may be complex to machine conventionally for the following reasons.
What Types of Parts Can be Machined By a 5-axis Machining Center?
5-axis CNC machining is applied chiefly where it is necessary to get complex shapes and contours for the part. Some of the components that are good to be machined using 5-axis machining include the following:
Special-Shaped Parts
The equal force cannot be applied in the machining of concave parts with complex geometry, such as points, surfaces, and lines, through conventional processes. However, 5-axis machining makes this more accessible and precise by using multi-station points, making it easy to cut such shapes.
Box Type Parts
Conventional machining practices are very demanding when it comes to machining box-shaped parts because of the multiple clamping and alignment. The 5-axis machine can operate on several planes simultaneously, which is beneficial when creating these box-type components.
Disc Parts
5-axis CNC machining is perfect for parts used in UAVs (Unmanned Aerial Vehicles). It is particularly suitable for the processing of plate parts, especially for the end-face or radial distribution holes. It is also ideal for making motor covers. The position of the holes in the machine determines whether a horizontal or a vertical machining center will be used.
Complex Surface Parts
Automotive, marine, and energy industries need parts with a surface finish that cannot be achieved by ordinary cnc machines. 5-axis machining is applied in the production of such parts as spherical ones, turbine engine blades, marine propellers, and impellers. This is made possible by the multiple axes of the machine that enable the making of such surfaces.
7. Get Precision Engineering Solutions From CNC Yangsen
CNCYangsen offers high-quality 5-axis CNC machining services to the aerospace, medical, and electronics industries. We can machine various materials like titanium alloy, aerospace aluminum, stainless steel, and engineering plastic because of the technological advancement in our production line and the professional team. We use modern technology and quality assurance measures that conform to the ISO 9001 standards to avoid this.
8. FAQ
Q1. How does five-axis CNC machining help in enhancing the accuracy of the part?
These systems control the machining parameters in real time, and the degree of variability is as low as ±0—005 mm for linear dimensions and ±0.1 degrees for the angular features.
Q2. What types of material can be machined with the help of 5-axis CNC technology?
Our specializations are in high-strength materials like titanium and Inconel, aluminum alloys, stainless steel, and other engineering-grade plastics like ABS, PLA, Nylon, and Delrin.
Q3. What surface finish options are available at Yangsen?
Due to advanced tooling and machining technologies, CNCYangsen can provide surface finishes of Ra 0.4 µm (16 µin). This capability is handy in applications with high resolution and low post-processing levels.
Q4. How does CNCYangsen ensure quality in 5-axis CNC machining?
At CNCYangsen, quality control is a process where the product is checked at some point in the machining process. We also use other modern measuring instruments, such as CMMs, to check the measurements of the parts and ensure that they meet the required standards. This commitment to quality is well illustrated from when a product is designed to its inspection time before it is taken to the market.