Our 5-Axis CNC Machining Services

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What is 5-Axis Machining?

This type of machining relies on a tool moving in five different directions around which the tool rotates. It is a multi-axis subtractive manufacturing process in which the machine shapes the workpiece material and moves in 5 directions or vertically.

The directions of movement include; X, Y, and Z, as well as A and B. 5-axis machining allows operators to approach part machining from all directions and axis in a single operation. Therefore, eliminating the need for manual workpiece repositioning between operations. Also, it saves time and is ideal for creating highly complex parts requiring precision.

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Advantages of 5-Axis CNC Machining

• 01

  Faster Material Removal

  5-Axis machining allows for the cutting tool to remain tangential to the cutting surface. Lower cycle times and costs are achieved because more material can be removed with each tool pass.This arrangement allows the tool to remove more material per revolution. As a result, it reduces cycle times and overall machining costs.

• 02

  Often Eliminates the Need for Complex Fixtures

  With 3-axis machining, complex fixtures must often be made to hold the part in the orientation necessary to create the feature. 5-axis machining eliminates the need and cost of creating the fixtures because the part can be held once and rotated to create the geometry.

• 03

  Simple Setup Operation

  Multiple setups (with 3-axis machining) are used to create the geometry by manually rotating the part for contoured parts or parts with machining on several faces. Using the 5-axis technology versus conventional 3 -0xis machining requires fewer setups to create a part with complex geometry.T he extra setup involved in manual machining compared to CNC machining can cause machinists to lose precise alignment during the manufacturing process. However, the minimal setup involved in 5-axis CNC milling reduces the possibility of errors and increases the accuracy required to achieve superior quality.

• 04

  Better Surface Finishes and High Accuracy

  Better surface finishes result by using the 5-axis capabilities on contoured geometry. With traditional 3-axis machining, very minor cuts must be used in order to create a good surface finish resulting in longer lead times. Less vibration further reduces the chance of "chatter" marks on the finished product. The vertical machining process also improves spindle utilization when machining inclined surfaces.5-axis machining also benefits when surface profile tolerances are required, particularly on complex contoured surfaces.

• 05

  Machining Complex Shapes (GD&T labeling)

  The additional rotation in this machining process helps to realize more complex designs and geometries. The machine can seamlessly machine arcs and angles that previously could only be achieved with multiple special fixtures. 5-axis milling process can rotate the part to achieve the desired geometry in a single operation without the need for complex fixturing.

  
  

  Additionally, the technology pairs well with GD&T marking to generate datum features in a single operation. 5-axis milling is also suitable for CNC machining applications that require surface profile tolerances on complex contoured surfaces.

How 5-Axis CNC Machining Works?

Design Guidelines of 5-Axis CNC Machining

Understand Machine Capabilities

Familiarize yourself with the specific capabilities and limitations of the 5-axis CNC machine that will be used. Different machines may have varying degrees of tilt and rotation ranges, which affect the types of geometries and angles that can be achieved.

Minimize Setups

Take advantage of the multi-axis capabilities to reduce the number of setups required. Consolidating machining operations into a single setup can improve accuracy, reduce lead times, and lower costs.

Avoid Overhangs and Undercuts

Design parts with considerations for accessibility and tool clearance. 5-axis machines can access more complex geometries, but deep cavities or undercuts may require special tooling or multiple setups, increasing costs and complexity.

Consider Machining Forces

Be mindful of forces exerted during machining, especially when cutting at extreme angles or depths. Properly support the workpiece and optimize tool paths to minimize vibrations and deflections, which can affect surface finish and dimensional accuracy.

Material Selection

Choose materials that are suitable for 5-axis machining. Consider machinability, tool wear, and thermal conductivity to optimize cutting parameters and achieve desired results efficiently.

Tolerances and Surface Finish

Specify achievable tolerances and surface finish requirements based on the capabilities of the 5-axis machine. Consult with your machining provider to understand realistic expectations and potential limitations.

Design for Rigidity

Design parts with adequate stiffness and support to withstand machining forces and prevent vibration. Consider adding features like ribs, bosses, and supports to enhance rigidity without compromising weight or functionality.

Collaborate with Machinists

Involve CNC machinists early in the design process to leverage their expertise and ensure designs are manufacturable. They can provide valuable insights into optimizing designs for efficiency and cost-effectiveness.

5-Axis CNC Machining Tolerance

How IDEAL Improve the Precision of CNC Machining?

Machine Calibration and Workshop Environment Maintenance

We Ensure that CNC machines are regularly calibrated according to manufacturer specifications. Keep machines well-maintained, checking for wear and tear on components such as spindles, linear guides, and ball screws.

Also IDEAL do best to maintain a stable temperature in the workshop to minimize thermal expansion of the machine and materials.

Cutting Parameters Optimization and Programming Techniques

Optimize feed rates and spindle speeds for the material and tool to achieve the best balance between speed and accuracy, and adjust the depth of cut to minimize tool deflection and chatter.

Use optimized toolpath strategies, such as adaptive machining, to minimize tool load and improve finish, and utilize software to simulate CNC operations to identify potential issues before actual machining.

Tool Selection, Management

Use high-quality cutting tools designed for the specific material and application, regularly inspect and replace worn or damaged tools to prevent inaccuracies, and select appropriate tool dimensions for the task to reduce vibration and improve cutting stability.

Fixture and Workpiece Stability

Use fixtures to securely hold the workpiece, minimizing movement during machining, and ensure that workpieces are properly aligned and set up before starting a job.

Operator Training and Quality Control in Processing

IDEAL Invest in comprehensive training for operators to ensure they understand machine capabilities and best practices.

We Perform in-process inspections and final checks using precise measuring tools such as coordinate measuring machines (CMM), and keep track of measurements and tolerances to identify patterns and areas for improvement.

5-Axis CNC Machining FAQs

• Q: Can 5-Axis Machining Provide Tight Tolerance?

  A:

  Yes, 5-axis CNC machining is renowned for its ability to achieve exceptionally tight tolerances. It can typically maintain precision within ±0.005 mm. This high level of accuracy is due to the machine’s capability to access five sides of a part in a single setup, reducing the number of setups required and minimizing errors associated with repositioning. The simultaneous movement along five axes allows for closer tool paths, ensuring precise adherence to design specifications, especially for complex geometries.

• Q: How Much Does Your 5-Axis Machining Service Cost?

  A:

  The cost of 5-axis CNC machining services can vary widely based on several factors such as the complexity of the part, the type of material used, and the required precision. Generally, prices might range from $75 to $250 per hour depending on these variables. For a specific quote, it’s best to provide detailed drawings and specify material requirements so that a more accurate estimation can be calculated.

• Q: When Should I Choose 5-Axis CNC Machining?

  A:

  Choosing 5-axis CNC machining is ideal in several situations where traditional 3-axis machining may not be sufficient or efficient. Despite the initial setup costs, 5-axis CNC machining can offer cost savings for complex parts by reducing labor, tooling, and secondary operation costs. It streamlines the manufacturing process and reduces the risk of errors and rework. In essence, choosing 5-axis CNC machining is beneficial when your project requires advanced capabilities to achieve complex geometries, high precision, efficient production, and superior surface finishes. Assessing your specific design requirements and production goals will help determine whether 5-axis machining is the optimal solution for your manufacturing needs.

• Q: How Quick Can I Receive a 5-Axis CNC Machining Quote?

  A:

  In most cases, we will respond to your quote within 1 business day. The best way to help ensure a quick quote is to provide as much accurate and specific information as possible.

• Q: What Would Typically Effect The Costs of 5-Axis CNC Machining?

  A:

  Several factors can significantly influence the costs of 5-axis CNC machining like Complexity of Parts, Material Selection, Quantity, Tolerances and Quality Requirements. Remember, while 5-axis machining might have a higher hourly rate, it often reduces the total production time and number of setups needed. Also, advanced machines can handle complex tasks more efficiently but may come with higher operational costs.

• Q: What Is The 5-Axis CNC Cost Per Hour?

  A:

  5 axis CNC machining is a special process, it’s machining cost is also higher. As for the specific cost figure per hour, it is hard to tell as it depends on several parameters. Among them, there are two major parameters: machine maintenance cost and management cost.
  At LDEAL, we are using 50cUSD per house for our 5 axis CNC machined parts cost calculation.
  However, it will vary depending on the different quality requirements. You can talk with our expert team if you want to have a solid quotation quickly.