This article will take an in-depth look at 5 axis CNC machining.
The article will bring more detail on topics such as:
This section delves into the essentials of 5-axis CNC machining, scrutinizing its structure, mechanics, and functionality.
While typical CNC machines function along three primary axes—X, Y, and Z�5-axis CNC machines integrate an additional two axes: A and B. These extra dimensions provide the capability to produce more complex and detailed parts with enhanced precision. This technology has seen increased utilization due to its ability to drastically reduce manufacturing time.
The rotating cutting tools in CNC systems swiftly shape the desired geometries with precision. By employing a table that moves and rotates across all five axes, strain on the cutting tools is decreased, which prolongs the CNC machine's operational life. Presented below is an illustration showing a 5-axis CNC machine.
5-axis machining represents a superior evolution from the standard 3-axis CNC method. This sophisticated, computer-guided mechanical technique moves tools across five directions with high accuracy to remove material efficiently, forming parts and components. The process begins with a CAD-designed concept, which is translated into precise CNC codes directing machine operations.
CNC machining provides high-standard results for various applications requiring both horizontal and vertical machine setups, including intricate turned parts.
The multifunctional nature of CNC machines allows for the efficient production of components in one seamless operation, including items like collars, bushings, fittings, fasteners, and spindles, to name a few.
A 5-axis CNC machine is structured with several essential components:
Diamond tools are typically employed for precise applications and feature cutting surfaces covered with diamond particles. Figure 1.3 demonstrates a machine table equipped with a spindle for gemstone cutting, showcasing the diamond tool's motion directions. These tools, specifically crafted for accurate edges, integrate diamond particles across their surfaces.
The selection of tool size correlates with the width of the cut and the desired post-machining surface finish. The diameter of the diamond particles applied to the tool aligns with the tool head's diameter. Primarily functioning along Z, X, and Y axes, the tool’s design facilitates precision. The B and A axes enable precise carvings of curved and arced patterns on workpieces.
For materials like sapphire and marble, which are notably brittle, the processed sizes usually do not exceed 60x60x60 mmÂł. Due to their extreme hardness, an abrasive machining protocol is used, with the diamond tool operating at speeds between 8,000 and 12,000 RPM. The tool's unique shape necessitates horizontal orientation, aligning with the plane of rotation. Below, you'll find the crucial design parameters.
| X, Y, Z linear motion Material size | 100 mm |
|---|---|
| Rotation angle of A axis | 180 degrees |
| Rotation angle of B axis | 360 degrees |
| Spindle Speed | 0 to 18 000 RPM |
| Cutting tool size | Φ(3 � 6)mm by 60mm |
| Material size | 60 by 60 by 60 cubic mm |
Established design principles guide the selection of primary parts and systems at the outset. Initially, the creation of CNC machines involves choosing core components and available systems while innovating new systems for specific needs. Below is an overview of the main components:
The design of a CNC machine encapsulates both its electrical and mechanical frameworks. Mechanically, the parts must be assembled to maintain stability and efficient energy transfer. The supporting frame ensures precise, flexible movement between elements, forming a cohesive apparatus.
The axes movements and spindle are aligned for optimal functionality. Mechanical system parts are designed, assessed, and simulated using Inventor software. An example 3D CAD model of CNC machinery is displayed above. Stepper motors drive the Z, X, and Y axes via ball screws, while timing belts drive the B and A axes. Initially, commercially viable parts were adopted, integrating other components for specific functionalities. B and A axis calibration ensures solid connections, effectively executed with durable materials. Key steps include leveraging timing belts to lessen motor torque and determining dimensions and ratios. Complete machine assembly, axis movement simulations, and component adjustments are achieved through 3D CAD simulations.
The CNC's electrical framework is tailored to support its operation. It uses a DC power setup with variable voltages: 5VDC for control inputs, 24VDC for motors, and 12 to 100VDC for spindle speed regulation. The electrical system's schematic is featured in Figure 1.5 below.
CNC machining relies on subtractive technology to sculpt parts using tools that carve material away until the desired shape is achieved. This design originates from a CAD file, which becomes a guiding G-Code program for the CNC system.
In contrast to most CNC milling apparatus that move on three axes (Z, X, and Y), 5-axis machines utilize additional axes to perform cuts from diversified angles, accommodating more complex layouts. The 5-axis system introduces axes A, B, and C for improved cutting flexibility.
A 5-axis CNC cutter approaches the workpiece from five perspectives. It traverses along Z, X, and Y axes while rotating across A, B, or C axes. Here are the axes and their movements:
With a 5-axis cutting apparatus, the Z, X, and Y axes twist in rotational angles to craft sophisticated designs with superior finishes. Axes A, B, and C freely rotate around Z, X, and Y. The CAD model or machine's configuration decides which extra axes are operated. Costs rise with this 5-axis arrangement due to the sophisticated calibration and automation technologies essential for precise functionality and command execution.
Here are important factors when selecting a 5-axis CNC machining approach:
The CNC control needs abundant processing strength to compute, regulate, and maneuver all moving axes concurrently.
For a 4+1 axis machine, a "look-ahead" function with 200 blocks is needed. Complex 4-axis sequences should aim for 400 blocks. For full simultaneous 5-axis machining, CNC control should have a look-ahead capacity of 1000 blocks or more for fast calculations.
A crucial, yet sometimes overlooked, aspect is the need for sufficient spindle robustness and power. A powerful spindle demands a robust foundation. For smooth cuts, it must withstand stress with a suitable power reserve. Some tasks may restrict those with an 11kW to 15kW spindle limited to 100 Nm torque. Initial savings on such spindles could prove costly.
Verify that the tool-holding arrangements are HSK or BBT to minimize vibration, ensuring optimal fit between the tool holder and spindle, regardless of conditions.
In line with machining needs, keeping a stable feed rate or adjusting to match cutting demands is vital. Thus, machines must adeptly manage and adapt cutting feed rates.
Comprehensive machine tolerance demands meticulous design and construction consideration.
This involves two main phases:
5-axis CNC machining offers enhanced efficiency and reduced error rates compared to more traditional methods. However, rigorous inspection remains necessary. Enhanced productivity is supported by stringent quality controls at every stage, with procedures addressing both documentation and processes.
Quality inspection for 5-axis systems incorporate three levels: tool precision, part validation, and process oversight.
Even with the accuracy of 5-axis systems, thorough inspection is paramount to ensure the final output meets customer expectations. Despite its technological advancement, such methods require consistent monitoring and management.
Effective heat control in the spindle is vital for optimal 5-axis CNC machine performance. By efficiently managing heat, the service life of crucial components is extended, improving overall quality and accuracy. Both spindle housing and nose require adequate cooling to prevent overheating during demanding tasks, which involve quick speeds and extensive machining sessions. For built-in motors housed within spindles, ensure tailored section cooling of both housing and nose.
5-axis CNC machines are uniquely engineered to deliver exceptional precision and machining versatility across a broad range of industries, including aerospace, automotive, medical device manufacturing, and mold making. These advanced CNC machine tools enable simultaneous multi-axis operations, complex part fabrication, and reduced setups, which contribute to shorter production cycles and improved surface finishes. Below, we present some of the leading 5-axis CNC machine manufacturers and their top-rated 5-axis models available in the United States and Canada, helping manufacturers and job shops identify the best solutions for their specific requirements.
The UMC-750SS by Haas Automation is a versatile 5-axis CNC machining center known for its robust construction, which ensures both stability and accuracy during high-speed operations. It offers true simultaneous 5-axis machining, enabling the precise production of complex and intricate parts often required in aerospace and medical applications. This model is equipped with a high-speed, direct-drive spindle for rapid and precise cutting, as well as advanced CNC control integration for easy programming and efficient workflow management. Its generous work envelope and automatic tool changer make it ideal for high-mix, low-volume as well as high-production environments.
The DMU 50 from DMG MORI is a compact 5-axis machining center designed to deliver high-precision part manufacturing across a wide range of CNC milling applications. It features a swivel rotary table and a swiveling milling head for true multi-sided and complex component machining. The high-performance spindle provides substantial torque and spindle speed for efficient, accurate, and flexible cutting—critical for industries demanding intricate geometry work. Advanced CNC control systems and proprietary DMG MORI software further enhance its machining capabilities, allowing for seamless machine automation, tool management, and process monitoring. These features help address user needs for flexibility, production efficiency, and user-friendly operation.
The VARIAXIS i-800 by Mazak is a high-performance 5-axis machining center that combines versatility with continuous productivity. It includes a tilting rotary table and a robust, high-speed spindle for simultaneous 5-axis machining of complex parts, making the machine suitable for advanced mold making, prototype manufacturing, and precision engineering. This model is equipped with Mazak's SmoothX CNC control for advanced multi-axis programming, real-time monitoring, and enhanced process optimization. Features like automatic tool changers, tool length measurement, and adaptive spindle control not only boost operational efficiency but also reduce labor costs, setup times, and cycle times—key considerations for machining job shops and OEMs seeking to improve profitability and machining flexibility.
The MU-4000V-L by Okuma is a vertical 5-axis machining center renowned for its high rigidity, precision manufacturing capability, and advanced automation options. It offers a spacious work envelope and a tilting trunnion table for highly versatile machining of various part sizes, from small components to large workpieces. Okuma’s exclusive Thermo-Friendly Concept minimizes thermal deformation, ensuring consistently tight tolerances and repeatable accuracy across long production runs. The model also features Okuma’s INTELLIGENT Technology suite, which includes high-speed spindles, adaptable tooling systems, and integrated process control for improved productivity, machine uptime, and ease of use—appealing to manufacturers requiring uncompromising accuracy and consistent process reliability.
The Robodrill α-D21MiB5 by FANUC is a compact, high-speed 5-axis machining center valued for its efficiency, repeatability, and precision in small-to-medium part production. It features a built-in motor spindle and an advanced simultaneous 5-axis drive system, enabling rapid and accurate machining ideal for electronic component manufacturing, medical device prototyping, and automotive parts. Powered by FANUC’s industry-leading CNC control platform, users benefit from intuitive programming, advanced tool path optimization, and remote monitoring capabilities that streamline workflow and boost shop floor productivity. In addition, the machine offers an automatic tool changer and efficient chip management system, both of which help reduce setup times and optimize high-mix part production.
When selecting the best 5-axis CNC machine for your business, consider key factors such as maximum part size, spindle speed, available CNC software, automation compatibility, precision requirements, and support services offered by the manufacturer. Most leading CNC machine builders provide a diverse range of models and options—such as integrated pallet changers, coolant management systems, and multi-tasking solutions—to meet the specific needs of different industries and applications. For the most accurate and current information on specific models, technical specifications, pricing, and after-sales support, it is recommended to consult directly with the manufacturers or their authorized distributors. Additionally, evaluating customer reviews, case studies, and third-party benchmarking can help guide your CNC machinery purchase decision to maximize return on investment and operational efficiency.
The primary difference between types of 5-axis CNC machines lies in the location of their rotational axes. In some 5-axis CNC machines, the rotation occurs by moving the table, thereby rotating the workpiece. In others, the rotation is achieved by spinning the tool head while the material remains fixed. Swivel head machines can handle larger and heavier materials since the workpiece does not need to be moved. In contrast, spinning table machines provide greater speed and stability for lighter objects.
This machine features a B-axis with a 360-degree rotary table positioned underneath the workpiece. It provides a workspace with a diameter of 50 inches and a height of 50 inches.
This machine is ideally suited for components with angled holes, such as turbine housings. These holes are positioned at various points around the outer diameter (OD) of the component. With this machine's design, transitioning from one hole to another requires movement in just one axis. In contrast, other types of 5-axis CNC machines would need to move in two or more axes to reach the next hole on a cylindrical component. However, with a pivoting head and rotary table machine, the apparatus only needs to be angled once to the correct position, and the spindle head must be oriented in the Z, X, and Y axes only once. Drilling a series of holes thus becomes a matter of retracting, feeding in, and indexing in the B axis to reach the next hole.
This approach results in a more repeatable process. Using additional axes for positioning increases the potential for positional errors. Another advantage of this machine design is its suitability for larger materials. With fewer rotational axes moving the material, the machine can more effectively handle large parts. Although the material is rotated around the B axis, this limited movement allows the machine to work efficiently with tall materials. In contrast, 5-axis CNC machines with both pivots on the table often have constraints related to material size due to their linear movement limitations. This design allows the machine to operate effectively on very tall cylindrical materials, as the material remains more fixed in place.
This CNC machine features a primary table so large that the A-axis unit can be oriented across a wide range of positions, offering increased flexibility. Efficient programming requires the programmer to precisely know the A-axis table face's position relative to the B-axis pivot. This often means the code is written with the assumption of a specific A-axis position, leaving the operator with the task of aligning the A-axis unit accurately to match these requirements. This alignment process can be time-consuming and requires careful configuration.
This CNC machine is ideal for components that require machining around the outer diameter (OD) of a cylindrical material, particularly when the component features holes or rings that need to be aligned with the spindle.
The machine is open, which can pose challenges for handling large parts if the axis components are not properly positioned. While it is equipped for 5-axis CNC machining, it has limitations on material size. When the A-axis component is in place, the material's volume is restricted by both the swinging around the A-axis and the practical size limits of the material that can be supported by the horizontal table surface.
Nevertheless, the extensive XYZ movement capabilities of the smaller 5-axis unit make this machine particularly well-suited for using long extensions or tools, especially when working at unusual angles.
The trunnion setup, also known as a Table-Table configuration, features both rotary axes integrated into the trunnion table, with the machining head remaining stationary. This configuration is familiar to many programmers and operators because it builds on the principles of standard three-axis CNC machining. The two rotary axes are often used to position the material precisely, making it straightforward to visualize the machine’s behavior and positioning during the machining process.
The trunnion table machine often provides superior undercut capabilities compared to other setups because the table can tilt further in one direction than a swivel head design. Additionally, the trunnion setup offers a larger effective work envelope. The table's ability to tilt and lock into position allows the X, Y, and Z axes to have their full range of motion. In contrast, a swivel head machine may require some of the work envelope to accommodate the tool length as the head tilts, which can be a limitation, especially when using long tools that significantly impact the work envelope.
The trunnion configuration is also advantageous for heavy metal removal. Since the head remains stationary, it allows for the use of belt-driven or geared spindles, which typically provide more torque at low RPMs. This stationary head design also reduces the risk of the head moving out of alignment during machining.
This type of machine can be configured in one of two ways: a head-head setup, where all rotational movements are performed by the head while the table remains fixed, or a head-table setup, which features a rotating table and a tilting head. Generally, these head-table and head-head configurations allow for the machining of heavier materials compared to the trunnion setup.
In this configuration, the table remains stationary, so the entire weight of the material is transferred directly through the CNC machine base to the ground. This makes the setup highly stable for handling larger parts. Additionally, compared to the trunnion design, the table's construction allows for accommodating larger materials overall, regardless of their weight. The rotating head also facilitates the use of shorter or average-length tools since all tool rotations occur above the material.
This chapter will explore the applications and advantages of 5-axis CNC machining.
Originally, 5-axis CNC machines were primarily used in the aerospace industry, but they are now widely adopted across various sectors. A 5-axis CNC machine can replace a 3-axis CNC machine, offering smoother finishes and greater efficiency. It reduces cycle times and minimizes the need for manual tool changes or component repositioning. In a 3-axis CNC machine, repositioning the component is necessary to machine all its faces, which can introduce alignment issues and human error. A 5-axis CNC machine eliminates these challenges by providing easy access to all faces of the component.
CAM and CAD software for 5-axis CNC machines can be highly advanced, offering numerous programming options. These tools often include collision avoidance features and post-processors for seamless machine integration. With the right setup, these programs can even facilitate "lights-out" CNC machining, where the machine operates unattended. 5-axis CNC machining is particularly useful for creating complex 3D shapes and performing traditional machining on angled or irregular surfaces. Some common industries that benefit from 5-axis CNC machining include:
Aerospace Applications: In the aerospace industry, 5-axis CNC machining is valued for its ability to produce contoured edges and smooth surfaces. Aerospace components are often geometrically complex, and the precision of a 5-axis CNC machine is crucial for achieving intricate details and interior cuts. Additionally, the machine's capability to complete a component in a single pass without repositioning enhances accuracy and efficiency.
Medical Device Manufacturing: In the medical field, 5-axis CNC machining offers significant advantages for manufacturers of implants, devices, and other precision parts. The high precision of 5-axis CNC machines meets the stringent standards of healthcare production. These machines are capable of efficiently producing small, intricately detailed components, saving both time and money through improved accuracy and streamlined processes.
Military Applications: 5-axis CNC machines are frequently used to manufacture precision parts for military devices. In addition to their aerospace applications, they produce components for submarines, compressor blades, turbines, smart weapons, sensors, high-performance engine parts, stealth technology, and even nuclear weapons. While not all components are military-related, nearly half of all 5-axis CNC machines are purchased for projects or contracts involving the American government.
Energy Equipment: 5-axis CNC machines are well-suited for producing specific and detailed parts required by the energy sector. When working with particularly tough or abrasive materials, these machines provide stability, making it easier to shape and cut the material. They also enhance process efficiency and reduce tool wear.
Additional industries that benefit from 5-axis CNC machining include pharmaceuticals and food processing.
Five-axis CNC machining facilitates the cost-effective production of intricate designs. The advantages of adopting five-axis CNC machining include:
With a five-axis CNC machine, you can access all surfaces of a component, except for the bottom and clamping areas. Unlike a three-axis CNC machine, which requires multiple setups and manual rotations to achieve complex geometries, a five-axis CNC machine completes the task in a single setup. This reduces the number of setups needed and saves time.
The additional movements provided by five-axis CNC machining allow for the creation of intricate designs and shapes. This capability enables machining of arcs and angles that previously required multiple setups and special fixtures. With five-axis CNC technology, complex fixtures are no longer necessary, as the part is held in place and rotated during a single process to achieve the desired geometry.
Every time a component is removed from a machine, precise alignment is often lost, impacting quality. Unlike three-axis CNC machining, five-axis CNC machining improves accuracy by allowing the entire job to be completed in a single setup. This method maintains precision and quality while producing complex shapes without compromising on the required accuracy.
In five-axis CNC machining, the cutting tool remains tangential to the cutting surface, which allows for shorter cycle times. This approach helps in removing more material with each pass of the tool, leading to increased efficiency and reduced machining time.
The additional fourth and fifth axes in five-axis CNC machining improve orientation and bring the component closer to the cutting tool. This allows for the use of shorter tools, which are less prone to vibrations at high cutting speeds, resulting in superior surface finishes. Additionally, this setup reduces machining time compared to a three-axis CNC machine, where smaller cuts are often necessary to achieve a good surface finish, leading to longer lead times.
While 5-axis CNC machining offers numerous benefits, it also has some drawbacks, including:
5-axis CNC machines and their associated software often require a higher initial investment compared to standard 3-axis machines. The overall cost of acquisition and maintenance can be significantly higher, with maintenance sometimes being more complex.
5-axis CNC machining involves two additional rotational movements beyond the three linear axes, making it more complex than 3-axis machining. Coordinating the movement of all axes to avoid collisions and ensure precise interpolation can be challenging. Complex programming is required to achieve optimal surface quality and machining precision, which may necessitate the expertise of a skilled programmer.
Operating a 5-axis CNC machine requires advanced skills for setup, programming, and operation. Skilled technicians are essential to manage the complexity of the technology effectively.
Despite these challenges, the advantages of 5-axis CNC machining generally outweigh the drawbacks. However, it is important to carefully consider the various challenges associated with adopting this advanced technology.
Travels and Available Capacity
Spindle Machining using CNC
Tool changer
Feed rates
5 Axis Size
5 Axis CNC Machining Electrical
Some considerations when maintaining 5 axis CNC machines are:
The primary advantage of 5-axis machining is its capability to produce intricate and complex parts with high precision. This efficiency significantly reduces production time from start to finish. By allowing the cutting tool or work table to rotate, 5-axis machining minimizes the risk of collisions and efficiently handles various part geometries without the need for reprogramming or additional machining.
Most CNC machine centers are based on the traditional 3-axis configuration, consisting of the X, Y, and Z axes. The 5-axis configuration expands on this by incorporating two additional axes, enhancing the tool's movement and flexibility.
5-axis machines typically include the following five-axis configurations:
Double Swivel Head Form - With the double swivel head form, two rotation coordinates control the direction of the cutter axis directly.
Droop Swivel Head Form - The droop swivel head form has the two coordinate axes at the top of the cutter with the rotational axis not perpendicular to the linear axis.
Double Swivel Table Form - In the double swivel table form, the two rotation coordinates control the space rotation, directly.
Droop Table Form - With the droop table form, the two axes are on the table, while the axis of rotation is not perpendicular to the axis.
One Swing, One Rotate Form - The one swing, one rotate form has two rotation coordinates with one on the cutter and one on the workpiece.
A 5-Axis CNC machine offers industries the chance to undertake jobs that they were formerly unable to complete. For manufacturers who presently use 3-Axis CNC machining, the advancement to a 4+1 or even full 5-axis CNC machine is the next logical step in their investment and production planning. Due to the price of such machines, nevertheless, it is advised that customers fully understand which procedures best meet the specific production requirements. There is also a need to pick the right CNC machine tool to realize the profitability and efficiency of production completely.
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