Milling is an important technology of CNC lathe machining, which has been applied to medical, aerospace, optical and other mechanical parts. Milling uses a rotating tool to remove material from the workpiece by feeding it at an Angle relative to the axis of the tool. The shaft of the milling machine determines the type of workpiece and the position on which it can be machined. Here we will show you the 3-axis and 5-axis machining methods, the difference between them, and which machining method to choose for your part.
What is 3-axis CNC
3-axis CNC machining generally refers to three axes that move in straight lines in different directions
- X-axis: The X-axis is one of the main linear axes of 3-axis CNC machine tools. It represents horizontal motion along the length of the machine tool.
- Y-axis: The Y-axis is the other main linear axis in 3-axis CNC machines. It represents vertical motion along the width of the machine tool.
- Z-axis: The Z-axis is the third main linear axis in a 3-axis CNC machine. It represents movement along the depth or height of the machine.
Advantage of a 3-axis CNC Machine
- Cheaper Processing Costs. The processing cost of the 3-axis machining machine is lower than that of other high-axis machines
- Cheaper Machine. Machining setup times are much shorter than 4-axis or 5-axis machines, and the machines are more affordable.
- Low Maintenance Cost.These machines require lesser maintenance due to the simple structure of the machine.
- Programming is simple.3-axis CNC requires simple programming. Simple alterations in the program can make any changes to the part.
Disadvantage of a 3-axis CNC Machine
- Low Precision.3 axis limits the accuracy of machining.
- Poor Flexibility. If the part has 6 sides to machine, operator has to flip the blank or change fixtures manually.
- Capabilities. 3-axis CNC machines cannot create parts with complex geometries.
When to Use a 3-axis CNC Machine?
- Limited Budget. Because the cost of machinery and processing is relatively low, so if you have a small budget, 3 axis is your best choic
- Simple Machining. When the surface of the part is the only position that needs to be machined, or your part structure is simple, you can choose 3-axis machining.
- Low Yield. Because the machine setup is simple and the processing time is short, it is suitable for orders with little demand.
What is 5-Axis CNC?
5-axis CNC machining tools have two rotary axes and three axes in linear directions. The 3 linear direction axes are consistent with the above 3-axis machines
Besides these, the rotary axes can be any two axes from the following three:
- A-axis: Rotary motion along the X-axis
- B-axis: Rotary motion along the Y-axis
- C-axis: Rotary motion along the Z-axis
Advantage of a 5-axis CNC Machine
- Saving Time. 5-axis CNC machines will help you save a lot of time. Shaft CNC milling will help get the job done quickly and efficiently in production. Requires a little bit of a single setup, which helps save cycle time and money. As such, it is a cost-effective solution to accelerate your final product to market.
- Maintain Optimal Cutting to Improve Cutting Conditions. In 5-axis machining, the tool is used to maintain the vertical state of the complex die machining surface, which can greatly improve the utilization of the spindle. The 5-axis machining principle is also applicable to the inclined side milling, which can eliminate the ribbed lines caused by the ball knife. This makes the surface quality of the mold more ideal, and also reduces the need for manual cleaning of the mold surface.
- High Precision. Through 5-axis machining technology, the problem of repositioning accuracy of the workpiece at complex angles is solved. It not only reduces time, but also greatly improves machining tolerances several times. The high cost of making multiple fixtures in the traditional way is also saved. 5-axis machining can process complex parts, such as drilling, taper machining, cavity recesses on complex surfaces, etc., which is impossible to achieve with traditional machining methods most of the time.
- High Production Efficiency. 5-axis machining can effectively reduce the processing time and auxiliary time of parts. It has a large spindle speed and feed range, so that the machine has a strong large cutting ability. Five-axis machining is entering the era of high-speed machining. The rapid movement and positioning of five-axis machining and high-speed cutting machining reduce the turnaround time of semi-finished products and improve production efficiency and accuracy.
Disadvantages of 5-axis CNC Machining
- High Cost. On the one hand, the cost of purchasing five-axis machine tools and the required software costs are high, much higher than the cost of ordinary three-axis machining centers. On the other hand, the maintenance of the machine itself is also more difficult than that of ordinary machines. These aspects also directly lead to the cost of 5-axis machining parts will be much higher than ordinary 3-axis machining.
- Programming Complexity. Because 5-axis machining is different from 3-axis, in addition to three linear movements, it also involves two rotational movements, and the spatial trajectory of the resultant motion is very complex and abstract, which is generally difficult to imagine and understand. For example, in order to deal with the required spatial free-form surface, it is often necessary to go through multiple coordinate transformations and complex spatial geometric operations, but also to consider the coordination of the movement of each axis, avoid interference, collision, appropriate interpolation exercise, etc. To ensure the required machining accuracy and surface quality, programming is even more difficult.
- High Technical Requirements for Operators. Five-axis machining is an advanced processing technology, and advanced technology requires the operation of higher level talents. From single programming to machining operation, it is different from the usual three-axis machine tool. As a result, highly skilled operators are needed, which also means higher labor costs.
When to Use a 5-axis CNC Machine?
5-axis CNC machines are ideal for the following situations:
- Complex Shapes: 5-axis CNC machining is the ideal choice when machining complex shapes.
- High Volume: High production volumes are handled very well with these machines. It can reduce the cost per part for high volumes.
- Precison Parts: Precison parts for sectors like R&D, aerospace, and medical parts require 5-axis machining.
- Multi-side Machining: Parts with features on every face require 5-axis machining process.
How to Choose Between 3-axis, 4-axis, and 5-axis Machines?
Choosing between 3-axis, 4-axis, and 5-axis machining can be easier if you know the factors to consider. Here are the things to evaluate when deciding between these methods:
- Cost: Cost is the primary factor for most manufacturers. For people on a budget, 3-axis machining is the definite way to go. You can consider 4 and 5 axis CNC machining only if the budget is not a concern.
- Application: Aerospace parts, medical parts, defence equipment, aircraft parts, dental implants, and other such applications require ultra-high precision. These precison parts can only be created with multi-axis machining like 5-axis.
- Part Shape: Parts with a simple form are suitable for 3-axis machining. You can save costs by opting for 3-axis machining for such parts. However, using 3-axis for complex geometry will mean additional costs and defects. In such cases, 4-axis or 5-axis is the better choice. The choice between these two can be made based on part geometry.
- Machining Process: If you already have a CNC machine, choice between the number axis can be limited. For instance, vertical milling machines are usually capable of 3-axis movement only. A milling machine with a rotary table is a 4-axis machine. Similarly, there are also CNC milling machines with 5-axis configurations.
- Production Volume: Choose the number of axes based on the production volume you want to manufacture. Small-volume manufacturing can be met with a 3-axis machining process. However, high volume production requires multi axis options.
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