5-Axis Machining Centers: A Professional’s Comprehensive Guide

Now that you’ve learned how a 5-axis CNC machine works, the question you may have is what are the advantages and disadvantages of such machines. Let’s look at them in detail.

Pros of 5-axis CNC Machine

Keys benefits of a 5-axis CNC Machine:

1) Minimized Machine Setup

With a single set-up process (aka “Done-in-One”), you can significantly reduce preparation time and increase both human and machine efficiency. This also reduces human and machine errors which result from working on multiple set-ups for each stage of machining. The simpler clamping equipment used to place the part in the required position in the machine also saves time, cost and reduces potential errors.

2) Machine Complex Shapes

With 5-axis machining, complex shapes and designs can be easily handled. This may include the following: parts of hydraulic systems, water pump housing, gear box housing, gear wheels, injection molds, oil & gas equipment, medical or blood transfusion equipment and many others.

3) Higher Machining Accuracy

By reducing the number of manual settings required, 5-axis CNC machine can help to improve the overall accuracy of the produced part.

4) Better Surface Finish

With a 5-axis CNC machine, the cutting tool can not only move closer to the workpiece, but also be positioned 90° to the part surface — this allows optimum cutting conditions at any time. The fourth and fifth axes (which are the rotational axis) allow shorter cutting tools that vibrate less, resulting in an improved surface finish. The main objective of the additional axis is to allow the cutting tool to reach all 5 sides on the part more precisely.

5) Faster Material Removal

Specifically designed to remove even toughest materials quickly and efficiently, a 4+1 or full 5-axis CNC Machine will significantly reduce any manual effort. This leads to greater efficiency and stability in machining.

6) Significant Time Savings

It is becoming more and more important to look into operation and manpower cost, given the rising costs of manpower, the lack of trained manpower and the need to increase factory productivity. Thanks to the all-in-one setting in such machine tools, operators do not have to re-clamp and move the parts to other machines for the next operation. Instead, they can focus on managing additional machines, hence increasing their productivity.

7) Significant Cost Savings

Improved tool life results in a lower frequency of replacement of new tools. Improved accuracy lowers the risk of costly mistakes or scraps. 5-axis CNC Machines further reduce floor space requirements, increases flexibility and spindle usage, decreases need for costly fixtures and lowers the overall inventory investment — all of this adds up to cost savings.

8) Expand Factory Capacity and Production Flexibility

For part manufacturers and contract manufacturers, investing in a 5-axis CNC Machine improves the flexibility of your productions. With its multiple applications, such machine tools allow you to maximize your machines for both large and small manufacturing orders. Such capabilities may not be present with lower cost standard machines that have clearly limited capabilities. 5-axis CNC machines are also ideal for today’s High Mix – Low Volume manufacturing environment, where mass production is less common than delivering machined parts in smaller batches which are repeated if the requirement arises.

9) Fewer Competition

5-axis CNC machines can significantly improve both your productivity and profitability. They set your manufacturing capability several notches above your competitors as they have ability to undertake a wider range of complex jobs with improved product quality, as well as catering to upcoming production demands.

Cons of 5-axis CNC Machine

Naturally, there are some drawbacks to a 5-axis CNC Machine. Here are some of the common disadvantages:

1) Costs

A 5-axis CNC machine and the essential software often requires an initially higher investment. The total cost of investment is often higher than the cost of standard 3-axis Machining Centers. Moreover, the maintenance required is often more complex.

2) CAD / CAM Programming

In addition to the three linear motions, there are two additional rotational motions involved, making 5-axis machining more complex than 3-axis machining. Consideration is also needed on the coordination of the motion of each axis, to avoid interference, collision, and the appropriate amount of interpolation motion.

To optimize the required machining precision and surface quality, complex programming may be a challenge, which may require the service of a qualified programmer.

3) Advanced Operator Skills Required

5-axis machining is an advanced technology where the programming, setup and machine operation require higher skilled technician.

From the above points, you can see that the benefits of using a 5-axis CNC machine tend to outweigh the cons. However, you should still consider the range of challenges posed when buying a 5-axis CNC machine. To avoid making expensive mistakes, consider undertaking a comprehensive review of your machining requirements before investing in such a machine tool.

In today’s challenging production and manufacturing environment, the absence of such highly flexible machining centers puts your machine shop at a significant disadvantage.

(You can request for our 5-axis Machining Centre catalogue or fill up the contact form for a consultation.)