A Handy Guide About 3 Axis vs 5 Axis CNC Machining
When considering the most reliable method to produce parts of varying complexity and at different speeds, the comparison of 3-axis vs 5-axis CNC Machining easily comes up. 3-axis machining is more basic, limited to only three linear axes, while 5-axis machining has two rotational axes for more versatility.
While the setup process for both is largely the same – part design, CAD model preparation, CAD to CAM conversion, and CNC machining – the capabilities and applications of the machining strategies differ.
3-axis machines are for simpler parts, while 5-axis machines produce complex parts easily, in a single setup.
What Is 3-Axis CNC Machining?
3-axis CNC machining is a machining system whereby the relative movement between the cutting tool and workpiece can occur in the X, Y, and Z linear directions. This implies movements in the forward-to-backward, right-to-left, and up-to-down directions.
3-axis CNC machining
These basic movements are enough to perform simple machining processes, such as holes, simple pockets, and simple contours.
What are the Advantages of 3-axis CNC Machining
A manufacturer may consider these 3-axis machining advantages and opt to use the setup:
- Relatively lower initial cost price
- Faster setup and programming
- Availability of support and expertise
- Simplicity and reliability from fewer moving parts
- Produces standard geometries
What Are The Limitations of 3-Axis CNC?
The limitations of 3-axis CNC machining include the following:
- Limited capability for complex part machining
- Multiple setups for complex parts
- Machining time may be more
- More handling
Examples of Parts Made by 3-Axis CNC Machining
Manufacturers use 3-axis CNC machines to produce various parts, including automotive parts, construction industry parts, and tools & fixtures.
Automotive Parts
Different car models use parts made by a 3-axis machining center. Examples of such parts are brake rotors and transmission casings.
Construction and Manufacturing Industry Parts
This is another major user of 3-axis machine-made parts. Common ones are hydraulic parts, fasteners, and shafts.
Molds & Dies
3-axis machining of a mold
With 3-axis CNC machining, it is easy to produce molds and dies, which are critical in different manufacturing processes.
What Is a 5 Axis CNC Machine and Machining?
A 5-axis CNC machine can move in the three linear axes of the 3-axis machine, plus two rotational axes. These extra axes rotate around the X-axis and B-axis, and are referred to as the A-axis and B-axis, respectively.
5-axis CNC machining
With these extra axes, the 5-axis machining center is capable of machining complex shapes in one setup.
There are two options, namely 3+2-axis CNC machining and simultaneous 5-axis CNC machining.
3+2-axis CNC Machining: The cutting tool rotates continuously during the machining process.
Simultaneous 5-axis CNC Machining: The machine utilizes a 3-axis program with the cutting tool fixed at an angle throughout the machining process.
What Are The Benefits Of 5-Axis Machining?
5-axis CNC machines provide the following crucial benefits;
- Enhanced part quality
- Reliable high-speed manufacturing
- Complex machining in a single setup
- Enhanced efficiency and production
What Are The Disadvantages/Limitations Of A 5-axis CNC Machine?
The 5-axis CNC machine also has limitations, which include;
- High investment cost
- Advanced programming requirements
- Common under-utilization of the machine’s capability
Examples of Parts Made by 5-Axis CNC Machining
5-axis machining centers are used in many industries, including aerospace, military, energy, and medical part manufacturing. The specific examples of parts are highlighted below.
Aerospace Parts
Geometrically complex parts for the industry include compressor blades, turbine impellers, nacelle parts, complex fasteners, and heat exchanger parts.
Military Parts
Complex, robust, and reliable parts for the military are made through 5-axis CNC machining. Examples are gun barrel parts, missile fins, and radar waveguide systems.
Energy Parts
The energy industry utilizes 5-axis machined parts such as gas turbine blades, pump impellers, and generator rotors.
Medical Parts
The medical industry is synonymous with precision-machined parts, including surgical instruments, orthopedic implants, and prosthetic joints. These and many more can be manufactured through 5-axis CNC machining.
5-axis CNC-machined medical devices
What Is The Difference Between 3-Axis and 5-Axis Milling?
The main differences between 3-axis and 5-axis CNC milling revolve around budget, part complexity, setup difficulty, and applications. 3-axis CNC milling is more budget-friendly and easier to set up, but its parts are less complex and accurate.
Part Complexity
The 3-axis CNC machine is limited to the X, Y, and Z linear axes. It can handle 2D operations perfectly, including machining different sides of a part. However, this requires several setups to achieve, which may increase machining costs.
Okay, Dovetail milling cutters and T-slot cutters may help produce undercuts using the 3-axis CNC milling machine, but more customized angled features can only be done on an advanced milling machine.
The 5-axis CNC machine can move freely along five axes, meaning it can easily machine more complex parts in a single setup.
Setup
Multiple setups and repositioning are part of 3-axis CNC machining when the part has multiple sides. This is different for 5-axis CNC machines, which typically require a single setup for complex or multi-faced parts.
Budget
3-axis CNC machines are more cost-friendly, whether you are looking at the initial investment or the long-term aspect. These machines have simpler designs and are easier to maintain.
The added complexity of 5-axis CNC mills comes at the expense of affordability. Smaller businesses may not be able to invest in this kind of machine.
Applications
The simpler parts of 3-axis CNC milling and machining in general are common in aerospace, automotive, and electronics. This method makes quality flat surfaces, panels, and machine covers, which are useful in these industries.
5-axis CNC machining is capable of producing parts that are more complex and relevant in military components, medical components, aircraft parts, and other intricate part requirements.
CNC-machined military components
Conclusion
To get the best from multi-axis machining solutions, businesses must differentiate between different systems, including 3-axis vs 5-axis CNC. If mostly in need of simple parts, 3-axis CNC is a good option, while 5-axis CNC is better for manufacturing complex parts.
ProleanTech provides quality parts for various industries using both 3-axis and 5-axis machining solutions. You can contact the team for more insights and to get a prompt quote for CNC machining services.
