While some may still consider five-axis machining in the context of complex aerospace, medical, and energy parts, there are strong reasons to believe the technology could be used in a wider range of applications. Even if you're not machining contoured surfaces, getting more part features in a single setup can have huge benefits for increased machine utilization and improved quality. There is no doubt that a five-axis machine is more expensive than a typical VMC, but the value of these benefits is considerable, and they will make your shop more cost-effective for a wider range of jobs.

When using three-axis machining, two, three or more settings may be required to get all the functionality of the part. Using a five-axis all-in-one approach eliminates those extra setup times, in addition to the potential for errors every time you reposition parts. For these reasons, the rationale for using a five-axis machine is simple, greatly reducing overall setup time, machining time.

Technology of five-axis machining

The easiest and cheapest way to get five sides of a part is with a 3+2 machine configuration. For small to medium machines, this usually means a three-axis machining center with a tilted rotary table to position the part. This can be done by using an auxiliary two-axis table on a standard three-axis machining center, which is a good first step for many shops. However, machines with an integrated tilt table generally offer better machining performance and are easier to set up and program. For 3+2 machining centers, such as a 2-axis rotary table, it is common to lock the fourth and fifth axes while machining the part. Nonetheless, almost any workpiece plane can be presented to the spindle and, surprisingly, complex parts can be cut efficiently.

For more complex parts, the ability to articulate at any angle relative to the workpiece will save hours, and also save the cost of tooling, compared to using a jig, sine plate, or other table to orient the part.

However, many shops quickly discovered that upgrading to a fully integrated 5-axis machine was more productive. On the one hand, it can contour simultaneously in all five axes, which is necessary for some part features. Full five-axis machines are also generally faster, able to reduce non-cutting time through faster workpiece indexing and higher machining rates using all axes, and are generally more accurate.

Advantages of five-axis machining

The main advantage of full five-axis control is that you can now tilt the tool dynamically into the kerf so that the tool vector remains constant as it feeds on a sloped or free-flowing surface. This is why 5-axis machining is so widely used for aerospace components, orthopedics and other parts with bending capabilities, and increasingly in mold and die machining.

The ability to dynamically hinge the tool to the workpiece also allows for more efficient use of the cutting tool. On the one hand, you can often use shorter tools because interference problems can be mitigated by tilting the tool holder or spindle away from the workpiece or fixing obstacles.

Also, by tilting the tool relative to the surface, you can use the effective groove length of the tool more efficiently. That is, you can make more cuts on the side of the tool than just on the end of the tool. This effectively increases the tool's cutting surface travel and can improve metal removal rates by as much as 40-50%.

Additionally, new tool designs designed for 5-axis machining are becoming more widespread. For example, circular segment milling cutters have various profiles that more closely match the contours or sloped surfaces of the workpiece. Shaping to have a larger cutting area on the side of the tool can significantly reduce finishing cycle times while still producing a better surface finish and blending from one surface to another.

Conclusion

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