In CNC machining, Simultaneous 5-Axis and 3+2 Axis machining are the two main types. Each has its traits and range of uses. Simultaneous 5-Axis can machine on five independent axes at once. It can handle very complex shapes and is best for high-end precision machining. 3+2 Axis adds two rotary axes to the traditional three-axis machining. Although it can’t do simultaneous machining on all five axes, it still offers better contact angles and higher efficiency for certain complex parts.
Next, Yonglihao Machinery will describe the specific uses, benefits, and selection guide for Simultaneous 5-Axis and 3+2 Axis machining. This will help you better understand these two machining technologies and find better solutions for your projects.
Table of Contents
What is Synchronized 5-Axis CNC Machining?
Synchronized 5-axis CNC machining tools move the cutting tool in five axes. Three linear axes and two rotary axes work together to machine the desired part. The table below shows the axes of a 5-Axis CNC machine and how they work.
| Axis | Working Manner |
| X-axis | Moves from left to right |
| Y-axis | Moves from front to back |
| Z-axis | Moves from top to bottom |
| A-axis | Rotates around the X-axis (tilts backward and forward) |
| B-axis | Rotates around the Y-axis (tilts from left to right) |
A and B are the two rotary axes which are known as tilting table axis and table rotary axis respectively. As can be seen from the way the axes move, 5-axis machining increases the movement of the tool spindle or table. As a result, the cutting tool moves and rotates more. This increases the efficiency of conventional CNC machining methods.
The fourth and fifth axes enable the CNC machine to machine five faces simultaneously. As a result, the 5-axis CNC machine is very precise and fast. In addition, it speeds up the process of manufacturing complex structures and features. Since it does not require much setup, the process is ideal for multiple uses and saves money.
What is 3+2 Axis CNC machining?
Standard 3-axis machining is usually accomplished by vertical and horizontal milling machines. However, tilting rotary trunnions and a rotary table are added to allow movement on two additional rotary axes. This approach is 3+2 axis CNC machining.
Positioning 5-axis machining is another name for this process. This is because the 4th and 5th axes hold the workpiece in a specific position. Instead of having to move all the way through the machining process, regular 3-axis machining operations can be accomplished. In addition, 3+2 axis machining centers have shorter and stronger cutting tools. This way, you can be sure of greater dimensional stability.
The 3+2 machining setup is even better than a standard 3-axis machining center. It can machine workpieces from all sides. In addition, it reduces the need for more setups in the manufacturing process. As a result, production lead times and costs will be reduced.
Compare 5-Axis Machining vs. 3+2 Machining
Setup is the main difference between 3+2 and 5-axis CNC machining. 5-axis CNC machines can move the cutting tool in five directions. On the other hand, in 3+2-axis CNC machines, 3-axis CNC machines are used with tilting rotary trunnions and rotary tables.
The types of products and industries that can be machined by 3+2 and 5-axis CNC machining are also different. 3+2 axis CNC machining is mainly used for flat surface machining. While 5-axis CNC machining is more suitable for machining surfaces with complex contours. As 5-axis CNC machining has more functions. Therefore it can machine parts of various shapes and functions for many industries.
However, not all projects require the use of synchronized 5-axis CNC machining. In some cases, a 3+2 axis machining method may be more useful. Therefore, you need to understand the advantages and disadvantages of 5-axis and 3+2-axis CNC machining in order to choose the best option.
Advantages of 5-axis CNC Machining
There are many benefits of using 5-axis CNC machining methods, such as the following:
Higher Precision
5-axis CNC machining requires fewer minimum settings, so there is less chance of error. And this improves the functionality of CNC precision machining, resulting in better results. With today’s 5-axis tools, you don’t have to change the angle of the cut piece. This means that the tolerances of the machined parts will be more precise.
High-Cutting Speed and Repeatability
With 5-axis CNC machining, the cutting tool is usually perpendicular to the surface being cut. This arrangement allows more material to be removed as the tool rotates. As a result, cycle times and overall machining costs are reduced. In addition, certain machine configurations allow you to use shorter cutting tools. This gives the tools a longer life and ensures that they can be reused.
Ability to Make Complex Parts
Since a 5-axis CNC machine can machine five areas simultaneously. It can therefore accomplish the cutting of curved parts and other parts with multiple surfaces. Since this type of machining has additional rotary axes. Therefore, it can handle more complex designs and geometries. In other words, 5-axis CNC machining can accomplish the desired shape of the part in a single operation and does not require complex fixturing.
Better Surface Finish
The extra axis of a 5-axis CNC machine ensures that the workpiece is properly aligned. That is, it brings the workpiece closer to the cutting tool. As a result, you can use a shorter cutting tool to produce the desired shape with minimal vibration.
The less vibration there is, the less likely there will be “chatter” marks on the finished product. Some CNC machines also make more use of the spindle when cutting angled areas. With this technique, you can achieve a better surface finish. In addition, this reduces the time and cost required for post-processing.
Reduce Costs and Cycle Time
In most cases, 5-axis machined parts can be machined in just one pass. This is because this method is very fast. Since the 5-axis CNC machine only needs to be set up once, it saves time and money. In addition, the use of shorter, more durable tools means that frequent changeovers are not required. This also saves machining time and costs.
Disadvantages of 5-axis CNC Machining
Although 5-axis CNC cutting is very useful, there are some problems. Here are some of them:
Higher Initial Cost
The cost of 5-axis CNC machines and the software they require is quite high. Whereas the price required for a 3 or 4 axis CNC machine is much lower. Similarly, the maintenance required for a 5-axis CNC machine is more complex than that of a normal machine. This factor also directly affects the price of 5-axis parts machining.
Unsuitable for Some Applications
There are some situations that do not allow the use of 4- and 5-axis machining techniques. For example, the cutting tool is too short or the shank is too wide. In such cases, it is not possible to prevent vibrations at inclined angles.
Complex Programming Required
Due to the 5-axis CNC machines have additional rotational directions and complex spatial paths. Therefore, more programming work is required to achieve the required machining accuracy, precision, and surface quality. In addition, 4-axis and 3-axis machining are more prone to errors compared to 5-axis machining.
Advantages of 3+2-axis CNC Machining
Compared to other CNC machines, 3+2-axis CNC machining offers the following advantages:
Manufacturing More Complex Features
With 3+2 machining processes, cutting tools can be shorter and harder. With these tools, you can create steep walls, undercuts in cavities, and many other complex shapes. In addition, the tools can be used in a specific way so that the cutting area forms a specific angle.
In addition, the spindle head can be moved down and close to the workpiece at the same time. Therefore, this method can also be used to improve accuracy and extend tool life.
Less Programming
The spatial trajectory of 3+2-axis CNC machining is smaller than synchronized 5-axis machining. As a result, the tool travels a shorter distance and its rotational motion is smaller. This makes programming for free-form machining easier.
Reduced Costs and Cycle Times
On most conventional 3-axis CNC machining centers, you have to stop the spindle several times to machine different surfaces. This can be very difficult if you need to machine five or more areas. 3+2-axis CNC machining, on the other hand, helps to solve this problem. You can use this method to machine five different areas at the same time.
Disadvantages of 3+2-Axis CNC Machining
When using the 3+2-Axis CNC Machining method, the angle between the tool and the grinding wheel usually remains constant. As a result, you may need many named views to display the surfaces of complex CNC parts. This usually leads to tool line crossings, which prolongs machining times.
Industries and Their Respective Machining Methods
CNC machining uses simultaneous 5-axis and 3+2 Axis technologies. These are used in many industries, especially aerospace, automotive, medical device manufacturing, and consumer electronics. They offer their unique advantages.
Aerospace
- Simultaneous 5-Axis Machining: In aerospace, this tech makes high-precision parts. These include turbine blades, engine housings, and complex spacecraft components.
- 3+2 Axis Machining: This makes larger, simple aerostructure parts like wing frames and fuselage assemblies. It is also a type of machining for large CNC machining.
Automotive
- Simultaneous 5-Axis Machining: To manufacture complex engine components, driveline assemblies, and customized body parts.
- 3+2 Axis Machining: It is widely used in making automotive molds. It also makes body parts and some standard parts.
Medical Equipment
- Simultaneous 5-Axis Machining: It is for making high-precision custom implants, surgical tools, and complex medical device parts.
- 3+2 Axis Machining: It is for making regular medical devices and extra tools. These include stents and housings.
Consumer Electronics
- Simultaneous 5-Axis Machining: For the production of complex mobile phone parts, camera assemblies, and micro-electronic devices.
- 3+2 Axis Machining: They make the parts for big consumer electronics. These parts include laptop housings and TV backplanes.
Cost Comparison
5-Axis machining is simultaneous. It offers unrivaled accuracy and handles complexity well. It dramatically reduces machining times and set-ups. But, it costs more and needs more skilled operators. 3+2 Axis machining is cheap. It makes programming and operation simpler. It is good for projects with limited budgets and less complex machining needs.
Related News: Cost Of CNC Prototyping A Cost Breakdown
Considerations for choosing a machining method
Manufacturers need to choose between the Simultaneous 5-Axis Service or 3+2 Axis Machining Service. They need to consider the following aspects:
- Part Complexity: For extremely complex parts, Simultaneous 5-Axis machining is necessary.
- Cost and Budget: When the budget is limited, 3+2 Axis machining may be considered.
- Machining Efficiency and Accuracy Requirements: Use Simultaneous 5-Axis technology for high efficiency. It’s for ultra-high precision machining.
- Technical Capability and Equipment Investment: Simultaneous 5-Axis machining needs more tech and equipment investment. Companies should choose based on their conditions.
Each method has its own advantages and uses. This requires a manufacturer with rich experience and technical capabilities, such as Yonglihao Machinery. We can provide the best solutions for your needs. This ensures the project runs well and the product is high quality.
Summary
When choosing between Simultaneous 5-Axis and 3+2 Axis CNC machining, the key is to understand their technical advantages and when to use each. Simultaneous 5-Axis machining is for high-end applications that need high precision and complex shapes. 3+2 Axis machining can be used in some less precise applications due to its cost and simplicity. Simultaneous 5-Axis machining is preferred for projects that require less precision. The right choice depends on the project’s needs, the budget, and the expected machining quality. Yonglihao Machinery can offer both technologies. They can recommend the best machining solution for the customer’s needs. This ensures a good balance between results and cost.
FAQ
What are the main differences between Simultaneous 5-Axis and 3+2 Axis machining?
Simultaneous 5-Axis machining enables precision machining in five axes at once. It is good for complex shapes and provides higher machining accuracy and speed. 3+2 Axis machining adds two rotary axes to the traditional three. But, they are not operated at the same time. It is suitable for parts with simpler requirements at a low cost.
Which industries benefit most from each type of machining?
Simultaneous 5-Axis machining: These machines are used in aerospace, automotive, and medical device manufacturing. They are also used in consumer electronics. They are especially used for applications needing high precision and complex shape machining.
3+2 Axis Machining: For simpler aerospace parts, use standard car parts. Also, for general industry and some basic consumer electronics.
How do budget considerations affect the decision between choosing Simultaneous 5-Axis and 3+2 Axis machining?
Budget is important for deciding whether to use Simultaneous 5-Axis or 3+2 Axis machining. Simultaneous 5-Axis machining costs more to use and operate. It is good for projects that need high accuracy and complexity. If the budget is limited and the machining needs do not require the high precision of Simultaneous 5-Axis machining, then 3+2 Axis machining will be a cheaper option. It will meet most of your machining needs at a lower cost.