Precision and speed are the two main factors defining any project’s success. From small to large-scale industries, no one compromises on precision. So, 5-axis CNC machining technology comes onto the scene to ensure both. There are also several other advantages of 5-axis CNC machining rather than precision.
Knowing those advantages helps you understand the true potential of this technology. You will also know why 5-axis machines are leading other manual machines. Are you new to this concept and don’t know why 5-axis machining is so powerful? Fret not! This article will explore the top-notch advantages of this high-tech process. Let’s get started!
What is 5-axis CNC Machining?
5-axis CNC machining is an advanced manufacturing process. This process cuts, shapes, and contours the workpieces. The machine used in machining can move along five axes; hence, it is called so. However, all these machines are computer-controlled. So, the precision level of this process is high.
Actually, 5-axis machining is an innovative version of the 3-axis machining. In 3-axis machining, cutting machines move along three X, Y, and Z axes. This process only offers linear motion for cutting machines. So, you cannot obtain an intricate design using this process. However, in 5-axis machining, cutting machines can move along five axes or directions.
Three axes are casual: X, Y, and Z. The Other two axes involve A and B, making this process stand out. But how do these angles work and help you create intricate designs? Let me explain it. The A-axis moves along the X-axis, and the B-axis moves along the Y-axis. This allows rotational movement of the cutting machines.
In simple words, you can cut the workpiece from any angle. Moreover, as I said above, these machines are computer-controlled. How do they work? Basically, a design model is created using CAD software. This design is converted into G-code using CAM software.
Cutting machines read these G-code instructions and cut the material. Since humans do not contribute, the accuracy level is excellent in 5-axis CNC machining. Besides precision, this process ensures high speed and saves time. Hence, the 5-axis machining process is used in aerospace, automotive, and marine industries.
Advantages of 5-axis Machines
I hope you have grasped the basic idea of the CNc 5-axis machining process. Right? Now, if we talk about the CNC 5-axis machines, they are not just tools. They are more than innovative and are game-changers for modern industries. What makes them so valuable? The answer lies in their advantages. Let’s dive in and explore the key benefits of 5-axis machines.
1- Higher Precision and Accuracy
Precision refers to how much the final product design matches the original model design. In contrast, accuracy refers to the accurate shape of the cuts, drills, and grooves. CNC 5-axis machines stand out in both terms. HOW? When you use the 3-axis CNC machines, they cannot reach the workpiece from different angles.
You need to change the position of the material every time. This results in the misalignment of cuts. However, this is not the case with 5-axis machines. The additional two axes allow them to reach the workpiece from any angle. There is no need to set them manually. As a result, you can obtain the precise design product.
Another factor that affects accuracy is unwanted vibrations. The rotational movement in the CNC 5-axis allows them to maintain the ultimate angle. This reduces the unwanted deflection of tools that affect accuracy. Lastly, a computer-controlled system of these machines reduces human errors. So you can obtain error-less results.
2- Increase Production Speed
CNC 5-axis machines are very beneficial in producing more products in less time. WHY? The reason lies in their high speed. We at BORUI CNC always focus on creating very quick machines. Prevision, in combination with speed, does the wonder. As I said above, CNC 5-axis machines do not require manual setup every time.
So, they remove significant material in one pass. As a result, products are obtained in less time. The second reason is the automation of CNC 5-axis machines. The design, toolpath, and cut shape are pre-defined. So, these machines need to follow those instructions and give quick results. So they help you increase production volume and meet the tight deadline.
3- Reduce Setup Time
In this fast era, everyone prefers speed in all manufacturing industries. Manufacturers want to produce more products in less time, right? This is only possible with reduced machinery setup time. So, 5-axis CNC machines offer this facility. Manual machines need frequent setups for each batch, which consumes time and reduces production volume.
However, 5-axis CNC machines require setup just once. As mentioned above, they can move the cutting tools with extra rotational axes. These axes help them reach every part without changing the setup periodically. Moreover, 5-axis CNC machines also can reposition and hold the workpiece by themselves. This reduces the setup time for new holding tools.
4- Production of Complex Parts
Production of complex parts is one of the top advantages of CNC 5-axis machines. You see the intricate designs of automobiles, airplanes, molds, etc. How are they made? Thanks to the CNC 5-axis machines. As mentioned above, these machines can approach the workpiece from every angle. This allows them to remove the material from any corner and create a complex geometry.
The creation of complex parts also requires a fixed setup. Frequent vibrations and movements can affect the design of those parts. However, CNC 5-axis machines cut the material with a single setup. Moreover, these machines use software to operate. So they can precisely create any complex model design you provide for these machines. You can create slots, pockets, grooves, holes, etc.
5- Higher Material Flexibility
CNC 5-axis machines have excellent flexibility for all types of material. No matter what kind of material you want to cut and shape, these machines will help you. You may wonder if some brittle ceramic and glass materials break with 5-axis machines. Right? But this is untrue. CNC 5-axis has an incredible ability to adapt to those materials.
They modify cutting edges, speed, and tool movement according to the nature of the materials. Moreover, 5-axis machines can also handle two types of material simultaneously. For example, you want your product design to involve metal and non-metal. These machines will handle both without changing the setup.
6- Long-term Cost-effectiveness
No doubt, CNC 5-axis machines have higher initial costs. The reason lies in their advanced design and the benefits they offer. However, considering these machines for the long run, they are cost-effective. HOW? As you know, CNC 5-axis machines are automated. So they do not require more staff to operate. Moreover, these machines can cut the material from all angles.
This removes the need for additional tools that save money. The CNC 5-axis machines produce defectless products. Those products do not require remanufacturing, which also saves on costs. The high speed of these machines also benefits in terms of cost. Lastly, CNC 5-axis machines have extensive durability and a long life span. It reduces the cost of maintenance and replacements.
Misunderstandings about 5-AXIS Machining
Despite its many advantages, 5-axis machining is often misunderstood. You must have heard several myths about this process and machines. Do these myths stop you from buying them? Worry not! In the section below, I will tackle all those misconceptions. Let’s jump right in!
Misunderstanding 1: 5-axis Machining is More Difficult to Operate Than 3-axis Machining
This is the most common myth surrounding CNC 5-axis machining. People think the advanced design of CNC 5-axis machines is difficult to operate. However, this is a wrong concept. Technology makes things easy for us, not tricky. So, 5-axis machines are also effortless to operate. They do not require frequent repositioning of the workpieces after every pass.
Once you set them and give them the instructions, they will provide the final results. However, some extra skills may be required to operate them. But it doesn’t mean they are impossible to learn. We at our company provide a complete user guide efficiently. With a little effort, you can efficiently operate the CNC 5-axis machines.
Misunderstanding 2: 5-axis Machine Tools Are Too Expensive
CNC 5-axis machines indeed demand higher initial cost. But they are not too expensive to buy. Even if you have a moderate-level business scale, you can easily buy them. After purchasing these machines, you will benefit from their long-term advantages. For example, CNC-5 axis machines increase the production volume of your business.
This way, you can regain the money you invested. Moreover, CNC-5axis machines also reduce material waste compared to 3-axis machines. Less material waste is a direct saving of money. You should also know that there are also some smaller CNC 5-axis tools. They are less expensive and offer the same benefits. But they are best for small-scale use.
Misunderstanding 3: 5-axis Machining Machines Are Not Suitable For Processing Large Parts
As you know, the CNC 5-axis machines create complex designs. So, people consider they cannot handle large parts. But the reality is that these machines can handle all sizes of workpieces. Whether you want to machine a small or large workpiece, these machines are suitable. You will be surprised to know that CNC 5-axis machines have adjustable worktables.
You can adjust their size according to the size of the material. Moreover, the cutting tools of 5-axis machines are very robust. So you can cut large and hard materials very easily. You can see the large and heavy components of automobiles and airplanes. All those parts are manufactured using these 5-axis CNC machines.
Misunderstanding 4: 5-axis Machining Machines Are Not Suitable For Beginners
Many beginners hesitate to buy CNC 5-axis machines. They think these machines are difficult to operate and cannot understand them. But the reality is something else. CNC 5-axis machines are user-friendly. They come with a software tool that helps you throughout the process. Moreover, some machines also have pre-programmed cycles.
It helps you operate the process without changing anything. Most of the manufacturers offer online training courses. They provide you with easy step-by-step guides. So in all these ways, you can learn everything about these machines. You can operate the CNC 5-axis machine with consistent learning in a few weeks.
Which Businesses Will Benefit from 5-axis Machining?
5-axis machining is more than just a technology. With flexibility and precision, it is helping many industries create better products. However, not all industries gain the same benefit from this technology. Let’s dive in and explore the most prominent businesses that gain the most!
- Setor aeroespacial: Aerospace is an industry that never compromises on precision. A slight mistake can lead to serious results. So, how can they gain that level of accuracy? CNC 5-axis machining is undoubtedly the best option. With 5-axis machines, they can create the most intricate airplane parts.
- Setor automotivo: Automotive industries are known for introducing new models of vehicles. They introduce modern and complex designs in automobiles. Moreover, creating complex geometry designs of engines and frames is also challenging. However, CNC 5-axis machines can quickly help them produce all those parts.
- Mold and Die Makers: Molds create plastic products. The accuracy of molds decides the accuracy of final products. So, those mold manufacturers benefit from CNC 5-axis machines. Moreover, dies used in metal casting need a higher level of precision. They are also manufactured using 5-axis machines.
- Defense and Military Applications: As you know, CNC 5-axis machines can easily handle all types of materials. So, they can help in the defense system by producing complex components such as radars. Moreover, missile parts, guns, and bullets are also designed using 5-axis machines.
- Energy Sector: Energy sectors involve power plants, wind, and solar plants. These sectors need turbines, rotors, and engines. How do they create such large parts? Actually, CNC 5-axis machining is the science behind it. So, the misconception about the 5-axis machines in handling large parts has also been removed here.
Perguntas frequentes
Q1: What is the difference between 3 and 5-axis CNC machining?
The 3-axis machining process uses machines that move only in 3 axes (XYZ). In this process, machines move linearly. So you cannot cut the martial from every side. On the flip side, 5-axis machines use two extra axes, A and B. These axes help the machines approach every angle. So you can cut the material at any angle without adding setup.
Q2: What are the names of the axes on a 5-axis CNC?
The names of axes in 5-axis CNC involve:
- X-axis: Move the machine from left to right
- Y axis: Move the cutting machines back and forth
- Z axis: Move the tools up and down
- A-axis: Rotates the machine at 180 degrees
- B axis: Rotates the machine at 180 degrees
Q3: How long do CNC 5-axis machines last?
CNC 5-axis machines have an extended lifespan as they are made with robust materials. However, proper maintenance is crucial to enhancing their lifespan. For example, you should check wear and tear frequently. Moreover, adequate lubricants must be applied before running them. Lastly, regular cleaning also enhances their lifespan.
Conclusão
CNC 5-axis machining is prevailing due to using advanced technology. This process used computer-controlled machines. In this article, I have explored the benefits and working of these machines. For example, CNC 5-axis machines work with CAM and CAM software. This software helps them create precise and accurate designs. These machines use an additional two axes.
These axes help the cutting tools approach from every side of the workpiece. Moreover, CNC 5axis machines increase the production volume. They are fast and produce more products in less time. Lastly, they benefit you with cost-affectiveness for the long term. If you aim for a large-scale business, nothing suits you better than CNC 5-axis machines.