CNC milling has revolutionized manufacturing by enabling the creation of highly accurate and repeatable parts. While 3 axis CNC mills are common, 5 axis CNC mills unlock more complex geometries and provide greater flexibility. This advanced CNC technology indexes the part in two additional rotational axes, allowing for sophisticated contours and deeply concave or convex surfaces.
5 axis CNC milling delivers higher precision, efficiency, and capabilities beyond conventional 3 axis systems. The additional rotary axes minimize excess tool changes and unnecessary refixturing that drive up costs and timelines. This enables streamlined production of complex parts out of metals, plastics, woods, foams, and waxes. From prototypes and one-off components to end use production parts, 5 axis CNC technology is the clear choice for top performance machining.
Defining 5 Axis CNC Mills
There are two main configurations of 5 axis CNC machining centers:
5 Axis Table/Tilting Rotary Table: The workpiece is mounted to a tilting rotary table oriented in the X, Y, and Z linear axes. Two rotary axes, A and B, tilt the part toReach the most impossible placed on the workpiece by orienting it without refixturing.
5 Axis Trunnion: The A and B rotary axes are built into the spindle head itself, which articulates to different angles in order to machine elaborate contours. A trunnion provides maximum range of motion and dexterity for the cutting tool.
Within these designs there are different kinematic variations that describe how the 5 axes move. Common architectures include XYZAB, XYZBA, XYBZC, and so on. Each has different advantages depending on factors like accessibility, collision avoidance, and simplicity of programming.
Benefits of 5 Axis CNC Machining
Compared to standard 3 axis CNC milling, 5 axis unlocks a wider range of geometries and machining possibilities:
- Access Undercuts and Complex Contours – 5 axis allows cutting into sides and areas a standard vertical tool cannot reach.
- Machine Multiple SIfdes Without Refixturing – By indexing the part at compound angles, all features can be machined in one setup without unclamping.
- Smooth Simultaneous 5 Axis Motion – Complex surfaces benefit from continuous adjustments over tilting and nodding motions rather than straight vertical plunges.
- Improve Finishes and Accuracy – Precisely orienting tools normal to surfaces produces superior finishes, tolerances, and edge quality.
- Reduce Machining Time – Less tool changes, quicker cycle times, and single setups mean faster production.
- Manage Long Reach Tools – Rearrange part angles to keep long reach cutters short for chatter reduction.
- Simplify Programming – Using 5 axis toolpaths and CAM software reduces manual G-code and post processors.
These capabilities make 5 axis technology ideal for industries like aerospace, medical, automotive, and more. Parts ranging from turbine blades, ported engine heads, prosthetic knees, impellers, and customized consumer products all benefit from the precision and flexibility of 5 axis CNC machines.
Considerations for 5 Axis CNC Mills
Integrating 5 axis systems does come at increased upfront costs over standard 3 axis CNC equipment. Other factors companies should consider include:
Equipment Cost – 5 axis CNC mills represent significant capital investment. However, efficiency gains can provide full ROI in under 2 years.
- Programming – While software has improved, programming 5 axis toolpaths requires higher skills over G-code. CAM software and 5 axis postprocessors continue progressing to simplify the process.
- Fixtures & Workholding – Additional rotary axes require part-specific fixtures and workholders capable of stable, rigid clamping in all possible orientations.
- Maintenance – Rotary components introduce additional components requiring preventative maintenance to operate reliably long-term. Schedule adequate inspections.
- Shop Environment – 5 axis systems take up larger factory footprints. Ensure adequate space, vibration damping, rigidity, and levelness for part precision.
The Future of 5 Axis CNC Mills
Even with the expanding capabilities of 5 axis CNC milling, future advancements promise even tighter accuracies, faster cycle times, and more user-friendly systems.
Ongoing controller and motor improvements will increase precision on micro-geometry details, surface finishes, and intricate structures. Automating machine setup, workholding, and tool changes also minimizes process variability while reducing manual labor demands.
Programming for 5+ axis systems continues progressing toward simplified push-button part production. CAM systems capable of collision detection, tool optimization, and post processors will minimize the need for extensive G-code knowledge. Paired with conversational programming interfaces on control pendants, future technology improvements will open 5 axis production to wider audiences.
As precision requirements and design complexities inevitably progress across industries, 5 axis CNC technology will only become more indispensable for flexibly meeting these needs. The unique geometries and efficiencies only possible through additional axes ensure 5 axis mills remain fixtures of high performance automated production.
