Modern manufacturing is constantly evolving. Technologies like 4-axis and 5-axis CNC machining enable us to meet complex design requirements, simplify production processes, and ensure high quality while reducing costs. These technologies not only increase production efficiency but also significantly improve product precision and consistency. In this article, Yonglihao Machinery will explore the key differences, advantages, and common applications of 4-axis and 5-axis CNC machining, and discuss how to choose the right CNC machining technology.
Choosing the right CNC machining technology is crucial for ensuring product quality and controlling production costs. By understanding the characteristics and applications of 4-axis and 5-axis CNC machining, manufacturers can better respond to changing market demands, achieve higher production efficiency, and gain a competitive edge.
Table of Contents
What is 3-axis CNC Machining?
Before you can understand how 4-axis and 5-axis CNC machines work, you need to know the basics of 3-axis CNC machines. This is because 3-axis CNC machines are still the most common type of CNC machining today.
In standard 3-axis CNC machining, there are usually three mechanisms involved in part manufacturing. The first is the up-and-down movement of the spindle. The other two are the forward-and-backward movement and the left-and-right movement of the spindle.
The Limitations of 3-axis CNC Machining
Three-axis CNC machines work in three directions, the X, Y, and Z axes. This is a good way to work. However, it also has some significant problems.
One problem is that the angle of the cutting tool remains the same. This makes it difficult to remove material from hard-to-reach parts of an object. In addition, you may need to set up a part several times. This is very time-consuming and reduces productivity. These problems are easily solved with 4- and 5-axis CNC machining.
What is 4-axis CNC Machining?
The above-mentioned problems are common in 3-axis CNC machining. 4-axis and 5-axis CNC machining are therefore becoming increasingly common. 4-axis CNC machining uses the same principle of action. But as you can see from the name, it has one more axis than 3-axis CNC machining.
A 4-axis CNC machine can move in three directions: up and down, left and right, and back and forth. The workpiece remains stationary on the machine table. In addition, a 4-axis CNC machine can rotate along the X-axis (also known as the A-axis). With this additional axis, a 4-axis CNC machine can do more when cutting or drilling.
In most cases, 4-axis CNC machining is better than 3-axis CNC machining. It makes the production process faster and more precise.
What is 5-axis CNC Machining?
The principle of a 5-axis CNC machine is very similar to that of a 3-axis CNC machine. However, it does have some very practical features. A 5-axis CNC machine has two additional axes and more cutting options.
In a 5-axis CNC machine, the spindle and cutting tool move along three axes. However, there are additional rotary axes on the X-axis (called the A-axis), Y-axis (called the B-axis), and Z-axis (called the C-axis). Depending on the setup, a 5-axis machine can use any two of these rotary axes.
Thanks to this feature, 5-axis CNC machining has a wide range of uses. It can be used for grinding, turning, and other operations. As a result, a 5-axis CNC machine can machine multiple parts.
3+2-axis CNC Machining
3+2-axis machining is a type of 5-axis machining. As the name suggests, it is a middle ground between 3-axis and 5-axis machining. In any case, it is a fast and efficient method of 5-axis machining. This type of machining is also referred to as positional 5-axis machining.
When you use 3+2-axis machining, the angle of the cutting tool remains the same. The grinding wheel or table is selected around the two additional axes. This means that the cutting tool is not always perpendicular to the part, and therefore cannot always produce a perfect cut.
However, there is a 3+2-axis machining process known as indexed 3+2-axis machining. In this form, you can manually change the angle of the cutting tool between cuts.
5-axis Simultaneous CNC machining
When the cutting tool always remains perpendicular to the part, this is called continuous or simultaneous 5-axis machining. This method produces smoother surfaces and makes it easier to machine hard-to-reach places. However, it takes longer than 3+2-axis cutting.
Differences Between 4-axis and 5-axis CNC Machining
The introduction of 5-axis CNC machining has greatly improved machining flexibility and increased the complexity of parts that can be machined. This technology can machine multiple faces in a single setup, reducing the need for repositioning and clamping the workpiece, thus enhancing productivity and reducing error rates. For complex geometrical parts requiring high precision, 5-axis machining is the optimal choice. Among multi-axis machining, 3-axis, 4-axis, and 5-axis CNC machining each has its unique advantages to meet different machining needs.
| Attribute | 4-Axis CNC Machining | 5-Axis CNC Machining |
| Rotational Axes | A-axis | A-axis and B-axis |
| Flexibility | Workpiece can rotate around one axis | Workpiece can rotate around two axes |
| Complexity Handling | Suitable for parts needing machining on multiple faces | Suitable for high-precision, complex geometries |
| Production Efficiency | Increases efficiency by reducing repositioning | Machines multiple faces in a single setup, greatly increasing efficiency |
| Applications | Aerospace parts, medical implants, precision components | Aerospace, automotive, medical devices, mold making |
Advantages of 4-axis CNC Machining
Efficiency and Precision：4-axis CNC machining adds an extra rotational axis (usually the A-axis), allowing the workpiece to rotate around the X-axis. This design enables machining on multiple faces in one setup, reducing the need for repositioning and clamping, thus improving production efficiency and precision. For example, in the aerospace industry, 4-axis CNC machining is commonly used to produce complex engine parts and propellers that require precise machining from multiple angles.
Cost Reduction： By enabling machining on multiple faces in one setup, 4-axis CNC machining reduces machining time and manual intervention, thereby lowering production costs. In consumer electronics, 4-axis CNC machining is used to manufacture metal phone and laptop cases, achieving efficient, low-cost mass production.
Versatility：4-axis CNC machining is widely applied in mold making and prototyping, capable of handling complex geometries and multi-face machining needs. This makes 4-axis CNC machining a crucial technology in fields requiring high precision and multi-face machining.
Benefits of 5-axis CNC machining
Extreme Flexibility and Complexity Handling: 5-axis CNC machining adds two rotational axes (usually the A and B axes), allowing the cutting tool to approach the workpiece from any angle. This flexibility enables 5-axis machines to perform more complex tasks, such as machining intricate surfaces and fine structures. In the aerospace industry, 5-axis CNC machining is widely used to manufacture turbine blades and structural parts that require precise machining from multiple angles to meet strict tolerance requirements.
Efficiency and Precision: 5-axis CNC machining can machine multiple faces in a single setup, reducing the need for repositioning and clamping, thus improving production efficiency and reducing error rates. In medical device manufacturing, 5-axis CNC machining is used to produce implants and surgical tools that require extremely high precision and complex geometries.
Reduced Tool Wear and Cost: Since 5-axis CNC machining can maintain the optimal contact angle between the cutting tool and the workpiece surface, it reduces tool vibration and wear, extending tool life and lowering production costs. In the automotive industry, 5-axis CNC machining is used to manufacture complex engine components and body structures that require high precision and complex geometries.
Increased Production Efficiency: 5-axis CNC machining can complete multi-face machining in one setup, reducing repositioning and setup time, thus significantly increasing production efficiency. For example, in the high-tech industry, 5-axis CNC machining is used to manufacture complex molds and high-precision parts, achieving efficient and precise production.
Application Scenarios
4-axis and 5-axis CNC machining technologies have unique capabilities and are widely used in many industries, greatly expanding the functionality of manufacturing.
4-Axis CNC Machining Application Scenarios
Aerospace Industry: 4-axis CNC machining is commonly used for parts that need machining on multiple surfaces but have relatively simple shapes. For instance, the aerospace industry frequently uses 4-axis machining to manufacture complex engine parts and propellers. The additional rotational axis in 4-axis CNC machining allows multiple faces to be machined in one setup, improving production efficiency and precision.
Consumer Electronics: 4-axis CNC machining is also used to manufacture metal phone and laptop cases. These products require high precision and smooth surface finishes to meet aesthetic and functional demands. 4-axis CNC machining technology enables fast, accurate mass production, ensuring product consistency and high quality.
5-Axis CNC Machining Application Scenarios
Aerospace Industry: 5-axis CNC machining is an upgrade from 4-axis CNC machining and can handle more complex shapes, such as parts with curved surfaces and hard-to-reach corners. This technology can create complex components through CNC machining of sharp internal corners. In the aerospace industry, 5-axis machining is widely used to manufacture lightweight and complex components like turbine blades and structural parts that require precise machining from multiple angles to ensure performance and durability.
Automotive Industry: In the automotive industry, 5-axis CNC machining is used to manufacture complex engine components and body structures. The technology allows multi-face machining in one setup, reducing repositioning needs and improving production efficiency and precision.
Medical Devices: 5-axis CNC machining is equally important in medical device manufacturing. It is commonly used to produce complex orthopedic implants and surgical tools that require high precision and complex geometries. The technology ensures the quality and performance of these medical devices, meeting stringent medical standards.
Mold Making: 5-axis CNC machining plays a crucial role in mold making, capable of manufacturing complex molds and high-precision parts. This technology not only improves the manufacturing precision of molds but also significantly shortens production cycles and enhances production efficiency.
How to Choose Between 4-axis and 5-axis CNC Machining
The choice of 4- or 5-axis CNC machining depends on a few key factors. These are part complexity, production volume, and budget. Understanding how these factors affect the decision process is crucial. It’s key to maximizing productivity and cost-effectiveness.
Complexity of the part: 5-axis CNC machining is often better. It’s a good choice if the part has complex geometry, needs multi-face machining, or has hard-to-reach areas. 5-axis machines can machine from almost any angle in one setup. This reduces how often you need to manually reposition the part. So, it keeps high accuracy. In contrast, if the part is simple or the machining requirements are not high, then 4-axis machining may be enough.
Production volumes: For high-volume production, 3- or 4-axis CNC machining may be preferable due to its lower running costs. However, for medium to small batches of precise parts, 5-axis machining offers extra flexibility. It also reduces manual work. This can lead to big time and cost savings.
Budget: 5-axis machines typically cost more to purchase and maintain than 4-axis machines. If the budget is limited, you may need to assess if the extra features of a 5-axis machine are needed. However, 5-axis machining can provide long-term savings and productivity. For some applications, it may be worth making a higher initial investment for a higher return.
When choosing between 4-axis or 5-axis CNC machining, you must evaluate the project’s needs. This includes the part’s complexity, the lot size, and the budget. The right choice will not only ensure a high-quality product. It will also boost productivity and be cost-effective.
Conclusion
We have discussed the benefits of 4-axis and 5-axis CNC machining. We covered where they apply and how to choose between them. These advanced CNC technologies are vital. They meet the modern manufacturing industry’s need for precision, efficiency, and complexity. It handles complex shapes. It also boosts productivity without raising costs. 4-axis and 5-axis CNC machining offer unrivaled solutions for the manufacturing industry.
If you have questions about how to use our 4- or 5-axis CNC machining services to meet your project goals, or if you need a detailed quote, the team at Yonglihao Machinery is happy to help. We look forward to working with you. We will use your designs to achieve your manufacturing goals.
FAQ
What is 3+2 axis CNC machining?
3+2 Axis CNC machining is a special type of CNC machining. It combines the features of both 3-axis and 5-axis machines. In 3+2 axis machining, the machine first uses its two extra axes (usually the A and B axes) to position the workpiece at the desired angle. Then, it uses the other three axes (X, Y, and Z) to machine in this fixed position. This method provides more machining flexibility. It avoids the complexity and cost of continuous 5-axis machining.
When should I not use 4- or 5-axis milling?
In some cases, using 4- or 5-axis milling may not be the best option. The part’s shape is simple. It does not need complex tilt angles or hard-to-reach areas to be machined. So, 3-axis machining may be enough. It will save cost and time. Also, for high-volume projects, simple designs may benefit from traditional machining. It can achieve higher productivity through simpler processes and lower equipment costs.