Reasons enough to invest in five-axis machining today. After all, they give you access to the five sides of a workpiece. With that alone, you can avoid a lot of extra set-ups and fixtures. Moreover, the technology has a lot of applications at a surprisingly affordable price. As the parts become more complex, the payback period will only get shorter because you also get the possibility to add special features and contours that would not be possible (efficiently) with classic three-axis technology. The range of five-axle machines on the market is now very broad. Here are a few pointers to help you stay on track.
Let's start by clearing up a misunderstanding. Five axles are not reserved solely for complex pieces. Yes, they can definitely make a difference compared to three-axis machines. But being able to chip on five sides can be enough of an argument for clamping simple pieces on them. After all, you save a lot of steps and the risk of something not being positioned quite right each time. The added value in this case is considerably less set-up time, machine time and fewer fixtures.
Second advantage that holds true even for simple pieces is the ability to use shorter tools. Indeed, the tools and tool holder can be tilted to avoid collisions. Especially when the tool holder would otherwise have to be extended to reach deep openings. Shorter also means less vibration and thus heavier or faster machining, better surface finish and longer tool life.
But which technology should you choose? For that, look at the pieces you want to make on it. How big are they? How much do they weigh? What tolerances are required? For those completely new to five-axis, machining centers with 3 + 2 axes can be an interesting stepping stone. Usually this is a three-axis machining center equipped with a tilting rotary table to position the part that can tilt. The fourth and fifth axes are fixed while the piece is being machined. Nevertheless, every surface of the workpiece can be offered to the spindle and even rather complex pieces are cut efficiently with it.
The next step is to add capabilities for full simultaneous operation. The advantage of this "full option" is that you can dynamically tilt the tool into the cut, away from interference or keep the vector constant as it moves over inclined or free-flowing surfaces. This is why five-axis machining is so popular for fabricating parts for aerospace, orthopedics or other industries where curved shapes are common. The five axes will also facilitate more efficient use of cutting tools for other pieces. Tilting the cutter relative to the workpiece surface supports better use of the cutter grooves, which are often cut with the side rather than the end of a cutter.
With a three-axle, you have few alternatives to a ball-head mill to generate contoured surfaces. Getting a smooth surface requires multiple operations with very small step-overs, which takes a lot of machine time and may require another secondary operation to smooth the notches. In five-axis machining, you can even use a flat cutter to generate some contour surfaces. The ability to access more edges of a workpiece is simply more pronounced with full five-axis control because the tool can dynamically tilt away from interference zones on the workpiece. Full five-axis control provides the ability to detail hard-to-reach shapes, such as the corners of chambers or lugs, while creating smoother surfaces. This capability can eliminate the need for secondary processes, such as sinker EDMs in mold and casting.
Why hasn't the entire industry switched to five-axis machining yet? Reason: part programming. However, CAM systems have evolved in recent years and have become much more user-friendly. These systems have features that allow programmers to create five-axis tool paths and still work largely within the three-axis context they are familiar with. This allows workshops to employ familiar cutting strategies supplemented by the additional workpiece features that five-axis machining offers. A "powerful machine tool" can no longer be defined by the machine itself. In today's IoT movement, software is a key factor in improving operational efficiency and production. As the number of machine tools increases, it is important to build efficient centralized machine control by using the latest network technology.
When investing in five-axis machining technology, it is important to think about how to make that equipment as productive as possible. This is why workpiece and pallet handling options are increasingly being used on these machines. With off-the-shelf automation solutions such as pallet changers, users can get more return on their machining investment. Automation also provides a solution to the skilled labor shortage that most workshops face today. With automation, five-axis machines can run for many hours with little maintenance required, maximizing workshops' investments in both technology and people.