Higher cutting speeds, faster drilling, better surface finish & reduced labour.

What is 5-axis
machining?

5-axis CNC machines are incredibly versatile manufacturing centres that benefit from employing up to five different axes simultaneously. Three linear axes and two rotational. Their capabilities are significantly more diverse than typical 3-axis CNC machines.

5-axis machines can be configured in such a way as to eliminate multiple setups and can thus reduce the need for constant supervision, increasing efficiency and achieving single-setup machining or “Done-In-One”.  View our range of 5-axis machines.

Aerospace Industry

One of the main reasons why 5-axis CNC machines are ideal for the aerospace industry is the limited amount of re-fixturing required. Due to the complexity of a typical aerospace component, 3 or 4 axis CNC machines will require multiple re-fixturing steps and re-orientations to allow for the cutting head to machine difficult to reach areas. Aerospace components also have organic shapes with compound curves which are an ideal application for 5-axis machines. An example of a compound curve can be found in turbine blades which are cast and typically machined by a 5-axis machining centre to achieve the final desired shape and surface finish.

Automotive Industry

The automotive industry is characterised by high production volume with a critical requirement for consistency. From the first to the thousandth, each component needs to fit within a specific tolerance every time. Most components in the transport industry are made using low-cost high-volume processes like stamping, injection moulding and casting. However, these cheap and fast techniques require advanced and highly accurate tooling, which is an ideal application for 5-axis machining.

Medical Industry

Like the aerospace industry the medical industry has an extremely stringent requirement for quality. Certain medical parts may have a direct and immediate effect on a person’s health or survival rate if there are detrimental quality issues. Some medical components have organic shapes machined out of exotic materials to enable them to be implanted into a patient. 5-axis CNCs can both machine these types of materials and handle the organic shapes of such implants. Apart from implants there is also a need for 5-axis on other medical-related applications like medical impellers and CT scanner components.

Energy Industry

The energy industry is the backbone of all other industries. It is vast and encompasses many different technologies. From coal-fired power stations to concentrated solar power systems and even more exotic technologies like fusion, there is a never-ending need for advanced components that push the limits of engineering, materials science and manufacturing. Due to these intensive requirements there is a need for machining systems that can reliably produce advanced components and this is where 5-axis machinery comes into its own. One example of the types of complex components that are emerging in the industry is the plasma containment chamber in a stellarator fusion device. The shapes in this machine are so organic and complex that there is simply no other way to manufacture them apart from with a 5-axis machine.

The Benefits of a 5-axis CNC Machine

Ability to produce more complex shapes

The most significant benefit of 5-axis machining is the ability to machine complex shapes and parts from solid that would otherwise have to be cast. This additional movement creates machining angles and arcs that were only previously possible with a multitude of special fixtures or additional setups. It can give lead times of one or two weeks, instead of two months or more that would be needed for castings.

Reduced re-fixturing

5-axis machines can machine nearly every visible surface, which reduces the need for multiple setups or special features. Due to the range of motion of its cutting head and extra rotational axes, these machines can reach 5 sides of a part, meaning there will be less re-fixturing required and fewer setups. This not only saves time, but also saves cost and operator error. Moreover, with multiple setups, there is always a possibility of incorrect alignment each time the part is moved.

Reduced labour cost-per-part

There are additional costs each time a machine operator touches a part. Through opting for a 5-axis machine, this wasted time and subsequent cost is eliminated. By reducing the time taken to re-fixture the part, this in turn also reduces the labour costs. The fewer the time an operator needs to touch a part the lower the cost will be.

3+2 axis machining

Certain parts are only able to be machined with a 5-axis movement, however, alternative parts can be machined more efficiently with a 3+2 movement. Here, the 4th and 5th axes are used to secure the work piece in a fixed position, therefore eradicating the need for all 5 axes to move simultaneously. 3 + 2 machining is perfect for parts with features on multiple faces or angles.

Better surface finishes

Using the 5-axis capabilities on contoured geometry directly results in a better overall surface finish in less time, in comparison to 3-axis machining where a good surface finish requires longer lead times. The use of shorter cutters in 5-axis machining reduces the vibration of the tool, allowing a higher quality surface finish to be obtained. This reduces, and can even eliminate entirely, the need for time-consuming hand finishing.

Feature-to-feature accuracy

There is the potential for inaccuracies in each setup change, once a part is removed from the machine and precise alignment can be lost. Using the same “Zero” or “Home” location means that feature-to-feature accuracy is maintained.

Faster cutting speeds

Due to its shorter tools, a 5-axis machine is able to get much closer to the material, which in turn allows for higher cutting speeds without putting excessive load on the cutter. This not only increases tool life but also reduces tool vibration and breakages. The machine also possesses additional axes of rotation – drilling compound holes at odd angles a great deal faster than traditional CNC machines as the head can be oriented along the correct axis for each hole automatically.

Increased opportunities in major markets

When making complex parts such as turbine blades, impellers and aerospace airframes, 5-axis CNC machinery maximises productivity by reducing the cycle times. As a result, this efficiency allows manufacturers to successfully compete for business in aerospace, automotive, medical and other major industries.

Improved floor space usage

By adding one 5-axis machine, many other machines can be eliminated or repurposed, therefore increasing the space available on the shop floor. These repurposed lathes, VMCs or HMCs can then be made more cost-effective by being used to produce less complex parts.