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.
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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.
The differences between 3 axis milling, 4 axis milling, and 5 axis milling can be confusing at first. We’ve created this guide to help you understand how each one works and which one will best suit your needs.
Starting with the basics, milling is a subtractive manufacturing process that uses rotating cutters to remove material from a workpiece. In other words, it’s how you create objects by shaping them out of other materials. Milling machines can be divided into three types: vertical milling machines, horizontal milling machines, and lathes.
These days, most machining operations combine several types of machines in order to achieve higher accuracy and precision. Milling only refers to these methods of cutting with machine tools. Although, there are more generic machining that include drilling, grinding and broaching, as well as, turning. So what does all of that mean? Let’s take a look at each one individually!
One of those types, lathes is a 3-axis CNC machine. 3-axis -CNC lathes turn a block of material around its main spindle, which runs vertically along its Z axis. A CNC lathe typically uses only two other axis. This includes one that runs left to right and one that runs in and out along a plane perpendicular to those of X and Y. These are both attached to swivel mechanisms called toolposts.
A variety of functions use the third axis that include cutting threads, drilling holes, and adding or removing material from parts on their way through production. Because it lacks an independent rotational ability on its own, a 3-axis CNC lathe can’t create objects with details smaller than one inch (25 mm) in diameter. Although this limits the machine, mechanics rarely need such small details since most manufacturers’ target customer bases.
CNC Horizontal Mill Machines are excellent for many industries such as precision machining, aerospace, nuclear and more! They have a complete X/Y axis with a rotary table as well as an X/Z axis. The rotary table helps you achieve perfect milling operations every time. How much load your job requires or what industry you are in will determine the need for machine power to correctly and efficiently complete the project.
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CNC vertical milling machines are valuable workhorses in a shop’s arsenal of metalworking machinery. They are capable of generating precision and power that far surpasses what a manual machine can achieve. Yet they are at a cost point that is much more accessible to most shops than CNC lathes or horizontal machining centers.
These machines have been around for decades and have become increasingly important over time as more shops automate their production processes. Here we will explore some of the differences between 3-axis, 4-axis, and 5-axis vertical milling machines.
In a three-axis milling machine, there are three axes of movement—the X, Y and Z axis. X axis means up/down, Y axis means left/right, and Z axis means forward, backward. The fourth axis allows for additional movement on all three axes at once, which makes it possible to do 3D milling on a part.
This is useful when drilling multiple holes along an edge that don’t perfectly align with each other; after one hole is drilled, more can be added along that edge without having to reposition the workpiece.
Lets take a step back to 3D milling. 3D milling is a type of CNC machining process that involves using computer software to send signals to a CNC milling machine that allows the part to rotate and move on 3 axes (X, Y, Z). machinists most commonly use 3D milling for rough cutting shapes out of raw material or carving fine details into a surface.
The machine uses a rotary tool bit or end mill as the cutting tool, which spins at high speeds (20,000 rpm) while it moves along one of its 3 linear axes. Depending on what part you’re working with, 3D milling can take place in either metal or plastic.
So why would someone want to go beyond basic 3D milling? There are actually quite a few reasons why someone might want to consider moving onto 4 axis and 5 axis machining: A big step up from basic 3D milling, 5 axis machines allow you to change both an object’s length and width during production—which essentially gives you freedom when it comes time to finish your parts.
5 Axis machines are similar to CNC milling machines and have a spindle along with four axes, but they also have an additional rotary axis that allows parts to be rotated freely in addition to moving them side to side, up and down or in any direction around a central point.
The additional rotating axis allows more room for creativity as it enables parts to be engraved, cut into or milled on all sides of a part instead of just one side like when using a CNC machine’s four axes. Although both types of machines can perform similar functions, 3 axis and 4 axis mills do so differently.
3 Axis mills use three moveable arms that move in front of each other along separate X, Y and Z planes. They provide movement while 4-axis mills use all three arms. This includes a fourth arm which moves in an A plane. This allows easy rotation around X/Y/Z axis. Because these two different types work differently there are also some differences between how they handle materials.
Unlike 3 and 4 axis milling machines, a 5 axis machine allows for more versatility in designs. With five axes of movement, you are able to move around any corner or surface with ease. This can create products that would be impossible on a traditional 3 or 4 axis machine. Plus, 3 and 4 axis machines only have two cutting tools at their disposal. There is one horizontal spindle tool that is always located above another vertical tool on a swivel.
So if you want to carve out something like an apple with your CNC router or mill, your horizontal spindle tool would have to do all of the work. This includes remaining perfectly parallel along its X, Y & Z axis’s while also maintaining contact with your material at all times.
On a 5 axis machine, however, there are 3 tools in total. These include one vertical tool and two horizontal spindles. This means much more intricate cuts can be made with greater precision due to being able to utilize both right angles on a single piece of material.
A five axes machine has a moveable head that can rotate on five different axes. As such, it can make a range of rotary and linear movements to create complex shapes in metal, plastic and other materials in applications such as aircraft parts, electronic devices and consumer goods. Not only does a CNC 5 axes machining center provide greater flexibility for making different shaped objects, but it also allows for higher speeds due to its precision capabilities.
The more moving axes means that these machines tend to be larger and heavier than their 3-axis counterparts. Most 5 axis machines are considered horizontal boring mills because they rely primarily on a rotary motion rather than a straight line path during machining. There are examples of vertical, 4 axis milling centers in automotive assembly lines.
A machinist can use 5 axis milling to make any complex contour. It is especially useful in mold-making applications, such as tooling for injection molding and die casting. There are complex 3D shapes that need to be replicated. They can also use five axis milling for multiple parts of an assembly at once on a single material stock.
By using a multi-axis system, they can easily make complex castings and deep pockets. They allow you to move each of your cutting tools in space. There’s no longer a limit on how far you can reach into or over your work piece without destroying your spindle bearings. Because five axis machines have become more mainstream, many companies who regularly perform large amounts of 3D milling use them. This includes toolmakers, aerospace companies, medical research facilities and universities are just some examples.
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