5-Axis Machining

5-axis machines rely on a tool that moves in five different directions — X, Y, and Z, as well as A and B, around which the tool rotates. Using a 5-axis CNC machine lets operators approach a part from all directions in a single operation, eliminating the need to manually reposition the workpiece between operations. 5-axis CNC machining saves time and is ideal for creating complex and precise parts like those found in the medical, oil and gas, and aerospace industries. There are a few different kinds of 5-axis machines that product teams should be aware of, including indexed 5-axis CNC machines, continuous 5-axis CNC machines, and mill-turning CNC centers.

Like 3-axis CNC milling, the cutting tool only moves along three axes and doesn’t maintain continuous contact with the workpiece in indexed 5-axis CNC machining. However, the machining table and tool head can automatically swivel in two directions between operations. Indexed 5-axis machining is great for manufacturing housings, jigs and fixtures. It falls somewhere between 3-axis CNC milling and continuous 5-axis CNC machining in terms of speed, precision, and the ability to handle complex geometries.

In continuous 5-axis CNC machining, the cutting tool and the workpiece can rotate and move simultaneously during operation, saving time and allowing operators to manufacture intricate geometries with organic surfaces. Continuous 5-axis CNC machining offers improved surface finish, speed, and dimensional stability, but it has the highest cost-per-part.

5-Axis Machining Applications

Automotive

5-axis machining is widely used in the automotive industry for the prototyping and production of car components.

These components include:

Engine housings

Engine covers

Valves

Inspection jigs

Light guides

Aerospace

Although turnaround times may be a big concern for some aerospace companies, complexity is the main reason why the industry is so dependent on 5-axis CNC.

Aircraft components often have intricate geometries — frequently including curves and interior cuts — that would take a long time to machine on a 3-axis setup.

5-axis machining can be used on all manner of titanium and aluminum aerospace parts, including:

Bulkheads

Fuselage sections

Landing gear components

Medical

Titanium and stainless steel surgical tools are frequently fabricated with 5-axis machining. These parts must be made to a high level of precision and are often made in large quantities, which favors the increased efficiency of a 5-axis CNC machine.

Machined surgical tools include:

Scalpels 

Forceps

Cutters

Spacers 

Clamps

Surgical scissors

Military

Large-scale 5-axis machine shops are frequently employed by governments for military projects, with 5-axis CNC suitable for the production of parts such as:

Turbine blades

Submarine parts

Engine parts

Sensors

Weapons

Electronics

In the electronics industry, 5-axis machining can be used to make essential parts for consumer electronic devices such as digital cameras and laptops.

Electronics casings and enclosures are often machined from plastic or aluminum, and 5-axis CNC is especially useful for chassis of irregularly shaped devices such as SLR cameras.

5-axis machining can also be used to fabricate parts like heat sinks — especially those with irregular or densely populated fin patterns. The efficiency and deftness of 5-axis also makes it easy to fabricate heat sinks in large quantities.

Molds

5-axis CNC machining can be used to cut deep mold cavities with minimal tool chatter and maximum precision. This is because 5-axis provides much better tool access to the workpiece, which in turn allows shorter cutting tools to be used.

All of this makes 5-axis CNC an appealing alternative to EDM, which is a much slower moldmaking process than CNC machining.

5 Axis CNC Process

5-axis machining is, as the name suggests, a form of CNC machining in which the cutting tool can move along five axes instead of the usual three.

With a 3-axis CNC machine, the spindle moves up and down, side to side, back and forth. 5-axis machines, in addition to this 3-axis movement, have two further axes in play: either the table rocks side to side on two different axes or the spindle itself swivels on two axes.

Either of these methods (more on their differences later) allow the cutting tool to approach the workpiece from an infinitely greater number of angles, and this makes it possible to create highly complex shapes.

It also reduces the number of setups needed: machinists don’t have to manually turn the workpiece over, because the cutting tool can simply reach more places. And this makes the entire machining process much, much faster.