5-axis machining is one of the most advanced machining techniques available today. Thanks to this modern process, parts of different shapes and sizes that cannot easily be machined on conventional machine tools can be produced. But what is 5-axis machining? Which machine tools carry out this process?
5-axis machining: a revolution for industry
5-axis machining refers to the number of directions in which the cutting tool can move. Conventional machine tools can move along certain planes, generally X and Y. In 5-axis machining centres, the cutting tool can move along the X, Y and Z axes, but can also rotate about the A and B axes, depending on the work to be done on the part.
Adding movement about the A and B axes allows the cutting tool to reach any angle and direction on the part – something that cannot be done, for example, on a conventional lathe, where the part has to be repositioned. This is the main advantage of this sophisticated machining process: all five faces of a part can be machined in one go, without repositioning the part or stopping the machine.
5-axis machining is one of the most advanced and complex metal-cutting processes. In addition, the machine movements can be performed by either the work table or the machine head.
Types of multi-axis machining
Two of the most advanced metal-cutting techniques are 3+2 machining and 5-axis machining. These are known as multi-axis machining cycles.
- 3+2 cycle: in this type of machining, the fourth and fifth axes (A and B) remain fixed. They can only move when changing from one operation to another; the other three axes – X, Y and Z – move simultaneously.
- Simultaneous 5-axis cycle: the most complex technique, as all five axes move at the same time. This allows the cutting tool to reach different angles on the part, shortens machining times and achieves a better finish.
Specific technology
Multi-axis machining is carried out on machine tools called machining centres, which operate by computer numerical control (CNC). However, for these machines to work, programming software is essential for designing the part: namely CAD (computer-aided design) and CAM (computer-aided manufacturing). Before the part is mounted on the machine, a computer must be used to design it; once the design is complete, it must be translated into an alphanumeric language using CAM.
The result is then loaded into the machining centre's computer, which tells the tools what movements to make to achieve the required result. These machines can also be programmed by the operator by entering a series of specific codes.
Features and advantages of the 5-axis machining centre
On a 5-axis machining centre, the first three axes correspond to the planes of the Cartesian X, Y and Z system; the fourth axis (A) controls the rotation of the part about one of the axes, which makes it ideal for machining cylindrical parts. The fifth axis (B) enables the rotation not just of one axis but of both simultaneously, creating a combination of rotations that allows greater freedom of movement. In addition, thanks to the fifth axis, a perpendicular rotation can be performed about one axis while the part is tilted perpendicular to that axis.
Furthermore, as machining centres are equipped with CNC technology, they can carry out not only very complex jobs but also different processes in one go. For example, a part can be turned while another operation is performed on it at the same time, such as improving the finish. On a conventional machine, this can only be done by stopping the machine and repositioning the part. The results are more accurate and shorter cutting tools can be used, which allows higher cutting speeds; this also reduces tool vibration.
5-axis machining is used for mass production, as this technique allows high-speed machining. Because complex shapes can be machined in a single process, productivity increases and not only production times but also labour are reduced; with CNC, a single operator can control several machines (all with CNC technology) at the same time. As a result, production costs also fall.
At Ferrotall we offer horizontal 5-axis machining centres from the German manufacturer GROB WERKE