Brief Introduction of the 5 Axis Machining
In the past, traditional machining has utilized three dimensions- the X axis, the Y axis, and the Z axis. And until today, 3-axis machining is still a very popular machining method to produce products and parts in the CNC field. But with the continuous development of the machining industry and the higher requirements for complex parts, 5-axis machining technology must appear in the public eye.
In recent years, 5 axis CNC machining centers have been used in wider fields. In practical applications, whenever people encounter the problem of machining special-shaped or complex parts, 5 axis CNC machining technology is undoubtedly an important method to solve such problems. More and more manufacturers tend to look for 5 axis CNC equipment for high-efficiency and high-quality machining. But do you really understand 5 axis machining?
Differences between 5 Axis Machining & 3+2 Machining
Some people may confuse the two CNC machining technology. So which processing method should we choose? And what differences between the 5-axis CNC machining and 3+2 axis CNC machining? Here I will make a brief introduction to help you out of confusion.
1. Definition
First of all, we can distinguish them from the definition. The true 5 axis machining is also named the 5-axis linkage machining. That means all five axes can be linked at the same time to process. While the 3+2 axis machining is in nature a 3 axis machining process. It is also commonly known as 5 axis positioning processing or false 5 axis machining. That is, additional two rotating axes are positioned to fix the material. And only the other three axes can process simultaneously.
2. Application
Second, they are suitable for different applications. 5-axis machining is suitable for surface machining and can realize various complex geometries with tighter tolerances. But 3+2 axis machining is more suitable for plane machining.
3. Tools
Third, 3+2 axis processing generally uses ball-end milling tools for processing. But the linear velocity of the bottom surface of the ball end milling cutter is zero, and the finish is also poor. However, the best 5 axis CNC machine for sale can completely overcome the above shortcomings and quickly engrave smooth surfaces.
How Does A 5 Axis Machining Center Work?
Depending on the materials being processed, the classification and working methods of CNC 5 axis machining centers may be very different. Below I will take the Blue Elephant 5 axis stone machining center and the 5 axis foam machining center as examples to show you the specific work flow of the five-axis machining center.
5 axis stone machining center
5 axis foam machining center
Why Choose 5 Axis Machining?
1. Simple setup
The best 5 axis CNC machine makes it possible to easily carve complex shapes in one setup. It doesn't need to be set multiple times, which can lead to bugs. Besides, a single setup helps reduce setup and manufacturing time and increases productivity. In addition to shortening lead times, the 5 axis milling machine also helps increase yield and product quality.
2. Faster cutting speed
Since 5 axis milling machine allows simultaneous movement along both the X axis and Y axis, shorter and stronger tools can be used. Moreover, using shorter and stiffer cutting tools can help speed up the cutting process with minimal or simply negligible vibration.
3. High accuracy
The workpiece does not move during the five-axis CNC machining process, which can achieve higher machining accuracy.
4. Superior Finish
Shorter tools are used in the 5 axis CNC machining process, which helps achieve the superior surface finish and better part quality.
5. Complex machining
Using the 5 axis CNC router, more complex machine parts can be made in less time and at a lower cost. And it is a big deal and beneficial for applications or prototypes running on a small scale.
What is 5 Axis Laser Cutting Technology?
Different from CNC 5 axis machining, 5 axis laser cutting technology uses the laser to cut and engrave products. A 5 axis laser cutting machine enables table tilt and rotation. It involves moving parts in five axes simultaneously and is ideal for bending parts and making corner cuts. Besides, it can machine 3D parts that require drilling and cutting on difficult surfaces or extreme angles.
Application of 5 Axis Machining Center in Car Mold Processing
1. Deep cavity mold processing
To use a 3 axis machine to process deep cavity molds, the tool holder and tool must be lengthened. But a five-axis machining center can create better process conditions for mold machining through additional rotation and swing of the workpiece or spindle head. Moreover, 5 axis machining can also shorten the length of the tool appropriately, so as to prevent the occurrence of a collision between the tool, the tool holder, and the cavity wall. In addition, it will also reduce the vibration and damage of the tool during processing. Therefore the service life of the tool is prolonged and the quality and processing efficiency are greatly improved.
2. Mold side wall processing
When machining the mold side wall, if the length of the 3-axis machining tool is increased, its strength will be significantly reduced simultaneously. And if the tool length is more than 3 times the normal length, it will even result in cutter relieving. Thus, it will greatly reduce the quality of the workpiece. But if the 5 axis machining center is used to process the side wall of the mold, the swing of the spindle or the workpiece can keep the tool and the side wall of the mold always in a vertical state. At the same time, face milling cutters of the 5 axis CNC router machine can improve the quality of the workpiece and prolong the service life of the tool.
3. Flat surface processing
When machining the flat surface of the mold, the 3 axis machining center needs to use a ball cutter for fine milling. However, the linear speed of the center rotation of the ball-end cutter is almost zero. In addition, the damage to the tool is greater, the service life of the tool will drop sharply, and the surface quality of the mold will also deteriorate. While using the 5 axis machining center to process the flat surface, the tool can be placed on the workpiece at a certain angle, which can increase the linear speed between the workpiece and the ball-nose tool. Thus, not only the service life of the tool can be prolonged, the surface quality of the workpiece will also be greatly improved.
4. Irregular surface processing
When machining molds with irregular curved surfaces, the cutting state of the tool tip of the 3 axis cutting machine cannot guarantee the perfect quality of each part of the mold. For molds with frequent curvature changes or deep grooves, they can be processed by a 5 axis CNC machine. The cutting tool can always achieve the best cutting state. And the tool can optimize the movement direction of the entire processing path. Besides, the tool can also perform linear motion at the same time. Every part of the surface of the mold is perfect.
5. Processing of different geometric shapes
When machining a mold with a 3D curved plane, the 5 axis machining center can change the working angle of the tool in any area. Thus, the machining of the geometrical mold is completed.
6. Machining of inclined holes on the inclined surface
When machining the inclined hole on the inclined surface of the mold, the five-axis machining center can place the spindle on the vertical side of the inclined surface of the workpiece through the oscillating head machining action. At the same time, it will also locate the accurate hole position. Then the machining of the inclined holes can be completed by a single movement of one of the linear axes of the main shaft. In addition, the accuracy of the hole can be significantly improved.
7. Milling of straight lines without direction change
To mill without direction change, as long as the tool tip draws a straight line. If the direction needs to be changed, the tool tip can draw a curve.
When the direction of the tool nose is changed, if you want a straight line, you must give this curve the necessary compensation. It is extremely important to apply a five-axis machining center. If the control system does not consider the length of the tool, it is very likely to move out of the current working position. Because the tool rotates around the center of the axis and the tool tip cannot be fixed. But the 5 axis CNC machining system can better control the 5 axes. Although the direction of the tool is changed, the position of the tool tip can remain unchanged. During this process, the necessary compensation movement of the x axis, y axis, and z axis is also automatically calculated. Furthermore, the machining accuracy is significantly improved.
Which 5 Axis Machining Center is Right for You?
Types of 5 Axis CNC Machine
5 axis CNC stone cutting bridge saw
A little different from other 5 axis machining centers, it is specially designed for cutting and engraving various kinds of stone materials like quartz stones, marble stones, granite stones, rock slabs, artificial stones, etc. It is an automatic and all-in-all stone 5 axis CNC machine for sale. For example, the 5 axis machining stone bridge saw can realize milling straight and inclined edges, chamfering, cutting arc edges, edge tracking, and so on. The most important is that it is equipped with the Blue Elephant 5 axis control system independently developed by us, which can perfectly achieve the stone processing effect that customers want.
How Much Does a 5 Axis Machining Center Cost?
If you are a 5 axis machining beginner, we don’t suggest you buy a used 5 axis CNC machine for sale. Though the second-hand 5 axis CNC router will be much cheaper, it will also be harder to maintain and operate. We Blue Elephant CNC Machinery can offer you the best cheap 5 axis CNC machine price. The CNC 5 axis machining center price usually ranges from $85,000 to $150,000. While the price of 5 axis stone bridge saw is from $30,000 to $40,000. This is just for reference. Because we also provide our customers with custom service for machine size and configurations. So the custom 5 axis CNC machine price will have a little difference.
Word at Last
The content described above summarizes most of the information on 5 axis machining. You can understand how the 5 axis machining center is processing. You will know what are the advantages of 5 axis machining and where to apply to. And you will learn how to distinguish 5 axis processing and 3+2 processing. In addition, you will also clarify the important role and application of 5 axis machining in the automotive mold industry. Moreover, this article can also give you ideas to buy the best suitable 5 axis machining center at a cheap cost.
This is why many customers are interested in 5 axis machining. If there is anything else I haven't mentioned or you want to know, please feel free to contact us. We Blue Elephant CNC Machinery will not let you down.
