In product manufacturing related to CNC machining, there is a lot to know about CNC machining axes. This is because of their importance and the fact that most modern CNC machines tend to operate using 4-axis and 5-axis CNC Machining.
In this article, you will get to know about 4-axis and 5-axis CNC machining. This will include introducing their basic principles, their differences, and how to choose one for your machining project.
To understand 4-axis and 5-axis CNC machining working mechanisms, you need to get a clear picture of 3-axis machining, which is still the most widely used form of CNC machining today.
A typical 3-axis CNC machining process involves three mechanisms in part creation. One is the spindle up and down movement, while the others are by moving it side to side and back and forth.
The 3-axis CNC machining work along three axes (XYZ). While this is a suitable way to work, it has some severe limitations.
One is that the angle of the cutting tool remains uniform which makes it harder to cut away parts of the material in hard-to-reach sections of the workpiece. Also, it may be necessary to carry out multiple setups for a part that drastically reduces productivity. These limitations are responsible for the more popular use of 4-axis and 5-axis CNC machining.
Based on the limitations of the 3-axis explained above, 4-axis and 5-axis CNC machining became more popular. The 4-axis CNC machining process encompasses the same mechanism of action. However, from its name, there is an additional axis included.
In a 4-axis CNC machine, the spindle travels along three axes: up and down, side to side, and back and forth, while the workpiece remains stationary on the machine table. The 4-axis CNC machining further rotates along the X-axis, also known as the A-axis. This extra axis allows the 4-axis CNC machining to function in situations that involve hole drilling or cut-outs.
Generally, 4-axis CNC machining is preferred to 3-axis CNC machining as it speeds up and improves the accuracy of the production process.
A 5-axis CNC machining process is also a lot like a 3-axis CNC machining process. However, it comes with some very important features that provide those two extra axes and a great deal more cutting flexibility.
On a 5-axis CNC machining, the spindle and cutting tool moves along three axes. However, there are other rotations on the X-axis (called the A-axis), Y-axis (called the B-axis), and Z-axis (called the C-axis). 5-axis machines can utilize any two of these rotational axes, depending on their configuration.
5-axis CNC machining is employed in different capacities based on this feature. It can perform milling, turning, etc. Therefore, you only need a single machine to work on several parts.
3+2-axis machining process is a subtype of the 5-axis machining process, which according to its name, is a kind of middle ground between the 3-axis and the 5-axis. Nonetheless, it is a rapid and highly effective form of 5-axis machining. It is sometimes known as positional 5-axis machining.
With 3+2-axis machining, the angle of the cutting tool does not change as the spindle or table rotates about the two extra axes. As a result, the cutting tool is not always perpendicular to the part, and it does not always create perfect cuts.
However, there is a form of 3+2-axis machining called indexed 3+2-axis machining. In this form, the angle of the cutting tool can be manually adjusted between cuts.
In 5-axis machining, when the cutting tool can always be kept perpendicular to the part, we have continuous or simultaneous 5-axis machining. This process can provide a superior surface finish and allows access to hard-to-reach areas. However, it is slower than 3+2-axis machining.
The major difference between the 4-axis and 5-axis CNC machining is centered on the extra axes they have, and this further leads to other subtle differences.
4-axis CNC machining has an extra axis, the A-axis, while 5-axis CNC machining has two extra, which can be A-axis, B-axis, or C-axis depending on the configuration.
4-axis CNC machining allows rotation on the A-axis, while 5-axis allows rotation on two of the three axes (A-axis, B-axis, and C-axis).
5-axis CNC Machining has an extra axis than 4-axis CNC machining. Not only is it an extra, but it is also not localized. Localized in this context means that 4-axis CNC machining extra axis is always on the X-axis. While that of 5-axis CNC machining can either be on two of XYZ axis. This extra and unlocalized property gives 5-axis CNC machining an extra edge over 4-axis CNC machining in terms of flexibility.
The features and functions of 5-axis CNC machining make it more costly than 4-axis CNC machining.
Regardless of their particular configurations, all 4-axis and 5-axis machines can move their cutting tools in more varied ways, and from a greater number of angles, than 3-axis machines. This allows for more complex machining operations and increased accuracy and can eliminate the need for multiple setups.
4 axis and 5-axis CNC machining provide numerous benefits from which you can decide the right one. This includes an increase in accuracy, a reduced setup time, and the potential for more complex parts.
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Other specific advantages depend on the machine configuration or whether there is a utilization of 3+2-axis or continuous 5-axis.
In general, 3+2-axis machining offers advantages such as:
Continuous 5-axis machining offers advantages such as:
4-axis and 5-axis CNC machining are important in many scenarios related to product manufacturing. Based on the one you want, they are useful in creating molds with deep cavities, creating complex 3D shapes, and machining on tilted surfaces of a part without compromising precision.
Of the two, 5-axis CNC machining can be used for a wide variety of parts. For example, it has become particularly dominant in the production of parts like impellers and turbine blades, which have contoured surfaces unsuitable for 3-axis machining.
Choosing between 4-axis CNC machining and 5-axis CNC machining for your project comes with understanding a thing or two. The three important things you must consider when choosing between both are:
On the budget scale, 5-axis is more costly than 4-axis, which is also more costly than 3-axis. The reason is the increase in capability, functions, and features as you move from 3 to 4 to 5.
For complex parts, you should go for the 5-axis CNC machining. However, for projects aimed at producing small and simple parts, 3-axis and 4-axis are ideal.
The higher you go in terms of axis number, the complex it is to operate. In situations that warrant an easy operating procedure, 3-axis is the simplest, followed by 4-axis CNC machining.
As a beginner, getting to know the disparity between 4-axis CNC machining and 5-axis CNC machining is one step toward making the right product. This is because most CNC machine utilizes the 3-axis, 4-axis, and 5-axis CNC machining process. Therefore, this article talks about the difference between the three.
Do you think of making use of one of the two processes in your project? Why not try us at RapidDirect? Our expert team is highly knowledgeable in CNC machining, and we can guarantee high-quality products tailored to your requirements. Get in touch with a member of the RapidDirect team or upload a quote via the link below. We’re at your service!
These days, CNC technology has evolved to include touchscreen controls, robots, and multiple-axis machines. For those that are brand new to the world of machining and bringing your manufacturing in-house, it’s daunting to figure out what kind of equipment you need. To provide a better idea of which milling machine and capabilities are best for you, we’ll explain the difference between a few types of machining: 3-axis, 4-axis, and 5-axis.
For 3-axis machining, the tool can move in three distinct directions independently or simultaneously relative to the material. It can move in the X, Y, and Z linear directions. In the case of a DATRON 3-axis milling machine, it’s back to front (Y-axis), side to side (X-axis), and up and down (Z-axis).
3-axis machining is great for sheet milling parts like panels and enclosures. It’s often used to make 2D and 2D.5 geometry. If you need to machine multiple sides of a part, that’s possible using multiple setups. Each orientation of the part gets set up and reconfigured in the workholding, which means more time is spent on the setups rather than milling the parts. There’s also more room for error with the fixture and aligning it to make sure the features are milled accurately. However, the DATRON next© control, integrated camera, and touch probe make it easy for even the most complex setups. Since precision and time are important factors in keeping production profitable, 4th and 5th axis machining may be more suitable depending on part geometry.
A 3-axis machine is well suited for operations like drilling, threading holes, cutting key slots, milling undercut features, cutting sharp angles, surface features, and features on the same plane. All these operations can also be done on 4-axis and 5-axis machines; the choice between them ultimately depends on your workflow, application, and budget. Complex geometries can be machined with 3-axis milling, but depending on the part’s geometry, 4-axis or 5-axis machining may be faster or necessary to reach certain features. If you need to make features that are on an angle to the XYZ coordinate system, 4th and 5th axis milling may be quicker and more precise.
There are different variations for 4-axis machining, but we will talk about vertical 4-axis milling. 4-axis machining has the same 3 axes (XYZ) as 3-axis, plus an additional axis for rotation. With a DATRON machine, it’s the A-axis. The A-axis has the workpiece rotate around the X-axis. The rotation allows 4 sides to be machined while the part stays in the fixture and needs only one setup.
There are 2 types of 4th axis milling: indexing and simultaneous (this is also the case for 5th axis milling). Indexing in 4-axis milling, known as 3 + 1, has the workpiece rotate into a position where 3-axis milling strategies are then used. For simultaneous machining, the part rotates, and the machine cuts it at the same time.
More complex geometries, like arcs and helixes, can be achieved more efficiently with 4th and 5th axis machining. You’re also able to cut angled features more easily. However, because the piece is secured in a single setup for 4th axis, the angled features need to be on the same axis. Otherwise, with different angled features, you adjust the setup (and possibly change the fixture) for each angle.
4th axis machining is often used when cut-outs and holes are on the side of a part or made on a cylinder. By using 4-axis instead of 3-axis, you typically save more time because you’re eliminating the need for additional setups. It’s also easier to hold tight tolerances on all 4 sides of a part since it stays in a single setup.
Like 4th axis machines, 5th axis machines also have their variations. The machines typically either use a rotation in the A-axis and C-axis or a rotation in the B-axis and C-axis. Both the workpiece and the spindle rotate in 5-axis milling. The two main types of 5-axis machining are simultaneous and 3+2 index milling.
For simultaneous milling, the cutting tool is in XYZ coordinates at the same time as the other two axes (A and C or B and C). This method allows highly complex 3D shapes and curves to be made. 3+2 does not have the two axes rotating at the same time. Instead, the rotation axes operate independently of each other, and the workpiece rotates to an angle in relation to the cutting tool. 5-axis machining allows manufacturers to create parts that were normally made using molds.
So, does this mean you need a separate machine for each type? Not necessarily. By adding trunnions or rotary axis accessories, 3-axis milling machines gain 4th and 5th axis milling capabilities. This is the case for DATRON CNC machines.
The DATRON neo, M10 Pro, and Cube Series are 3-axis milling machines available for upgrades with DATRON accessories. The M10 Pro and Cube series’ machine beds have cut-out options for 4th or 5th axis accessories. The neo can do 4-axis milling with a rotary axis accessory. There is even a 5th axis DATRON machine, the C5, which is used for micromachining small, precision parts.
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