5-Axis Machining

5-Axis Machining

A highly accurate machining technique that produces mission-critical components according to your specifications with fast lead time and efficient surface finish.

Premium Parts offers state-of-the-art 5 Axis CNC Machining that overcomes the limitations of traditional machining and manufactures parts with extreme precision and efficiency without the need for multiple setups. Our 5 Axis CNC Machining services make it possible to create custom parts with incredibly complex multi-axis geometry on schedule and within your budget. We provide the ability and capacity to deliver your custom 5 Axis CNC Machined parts using materials such as Titanium, Stainless Steel, Aluminum, ABS, and PP, etc. Our skilled experts and quality assurance are designed to produce the best results that meet your standards and requirements with high levels of consistency and flexibility. Work with us as we effectively manufacture accurate components for your business with our reliable and proficient 5-Axis machining.

What is 5-Axis Machining?

5-axis machining uses a simultaneous motion of cutting tools or parts along five axes utilizing a computer numerical control (CNC). Every cutting tool's axis is constantly moving to align the cutting tip to the component. This process effectively manufactures various complex parts with extreme accuracy in any shape or size.

Traditionally, machines have often been either one-axis (such as a drill that only operates up and down on the y-axis) or three-axis (a machine that can run up and down on the y-axis, left and right on the x-axis, and forward and back on the z-axis). For 5-axis machining, the user gets two additional axes: A-axis (the tilting table) and C-axis (the table rotation).

How does 5-Axis Machining work?

The work piece is manufactured to its desired shape in CNC machining using high-quality cutting tools and subtractive machining technology. The original CAD (Computer-Aided Design) file predetermines the form. Afterward, a program in G-Code format is created, feeding the CNC machine with instructions.

Presently, three axes—X, Y, and Z—are most commonly used for CNC milling machines. However, 5-axis CNC machines use extra axes to incorporate cutting from different angles, allowing them to manufacture more complex and intricate patterns. As a result, axes A, B, and C can be shown. These axes coordinate with X, Y, and Z in rotating angles to produce a 5-axis cutting machine capable of complex designs while maintaining a high standard for the final product. The A, B, and C axes rotate independently from the X, Y, and Z axes. It depends on the specific machine setup or CAD design to determine which two of the other three rotating axes are used. Due to the greater degrees of automation and calibration technologies required to operate the CNC machine and input commands, this 5-axis setup can be more expensive. Premium Part's 5-axis machining is a major engineering technology in the automotive, aerospace, and medical industries, among many others, and can provide the best precise engineering solutions.

Types of 5-axis machining styles

There are two styles of CNC machining operating with a 5-axis:

Trunnion Style

This style operates with an A-axis rotating around the X-axis and a C-axis revolving around the Z-axis. The trunnion machinery has movable tables, which helps cut large volumes as no spindle takes up extra space.

Swivel Rotate Style

The B axis revolves around the Y axis and the C axis rotates around the Z axis in a 5-axis swivel rotating machine. This process is different as the table is constantly horizontal during cutting, making it easier to handle heavier parts. The rotary axes represent the swiveling cutting arm.

Benefits of using 5-axis machining

Easy single setup

3-axis machining involves various setups, which might lead to increased costs, time and other complications. With 5-axis machining, you can create complex forms in a single format, increasing productivity, saving time and money, and preventing human errors.

High-cutting speed

A 5-axis machine has shorter tools that reach close to materials enabling faster-cutting speed without putting excessive pressure on the cutter. This method also lessens tool vibration and breakages and extends the tool's life. Shorter cutting tools helps eliminates cores and cavities as they have less vibration and provide a superior surface polish.

Hole drilling

Using 5-axis machining, it is possible to drill several holes with different compound angles quickly. This saves a lot of time since, compared to a 3-axis machine, each hole would require a different setup.

Create complex pieces

Using this method, you can manufacture complex parts that generally need casting. With this extra mobility, it can machine angles and arcs that were previously only possible with a large number of specialized fixtures or additional configurations. Instead of waiting months for the casting to be completed, you can manufacture your components in a few weeks if you need a few copies or prototypes.

Increased tool life

Maintaining a steady chip load and the ideal cutting position may extend the tool's life and cycle time without needing expensive fixtures.

Prevents collision

The 5-axis machining can tilt the table or cutting tool to avoid collisions with the tool's holder.

Applications of 5-axis machinery

5-axis machining is significantly used in various industries, especially applications requiring parts with complex designs and tight tolerances. These industries include:

Aerospace Industry

Although certain aerospace businesses may have serious concerns about turnaround times, complexity is the main reason for the industry's reliance on 5-axis CNC. This is due to the complicated geometry of several aircraft components (which typically include compound curves and inside cuts) that would take a long time to manufacture using a 3-axis system. The following titanium and aluminum aircraft components can all be machined using 5-axis machinery:

  • ● Fuselage sections
  • ● Landing gear parts
  • ● Bulkheads

Automotive Industry

The automobile sector strongly needs consistency and has a high manufacturing volume. Each component must always fit within a specific tolerance, which is why they rely on 5-axis machinery to produce parts with highly accurate results. Some of these parts include:

  • ● Valves
  • ● Engine housings
  • ● Engine covers
  • ● Light guides
  • ● Inspection jigs

Medical Industry

5-axis machining is widely used to create surgical instruments from titanium and stainless steel. This procedure helps to frequently produce in large quantities and with high precision on time. These instruments include:

  • ● Spacers
  • ● Clamps
  • ● Scalpels
  • ● Forceps
  • ● Cutters
  • ● Surgical scissors

Energy Industry

Due to advance and emerging technologies, the 5-axis machinery excels at producing the use of advanced components with specific and strict requirements. One of the examples is the plasma containment chamber in a stellarator fusion device, a complex component now emerging in the industry. Due to their intricate and organic structures, the 5-axis machinery is the only way to manufacture these parts with high accuracy and minimal errors.

Military

Government agencies frequently use large 5-axis machine operations for military projects for producing parts such as:

  • ● Turbine blades
  • ● Engine parts
  • ● Sensors
  • ● Weapons
  • ● Submarine parts

Electronic Industry

5-axis machining can produce essential components for consumer electronics like digital cameras. Electronics enclosures and casings are commonly manufactured from plastic or metal, and 5-axis CNC is beneficial for the chassis of devices with asymmetrical shapes, like SLR cameras. They can also produce parts like heat sinks, especially those with irregular or densely packed fin patterns in bulk quantities.

5-axis machinery is now a staple for industries as it can create complex parts and geometries with accurate dimensions. They may greatly improve the process of most production activities and are ideal for components with tight tolerances and high resistance standards. A 5-axis machine can easily approach the element closely from every angle in a single operation. It also reduces the need to reposition the workpiece between processes manually. In addition to saving time, 5-axis CNC machining is the best method for producing complex and accurate parts for major industries such as aerospace, oil and gas, and medical. The 'done-in-one' single setup method of 5-axis machines and exceptional accuracy and precision will only soon become the standard for industries in the near future.

Why choose Premium Parts

Quality material and finishing

We provide exceptional machining services with a wide selection of production-grade materials and finishing solutions to enhance your project’s visual appeal and functionality.

High consistency and performance

With our quality control system and manufacturing standards, we guarantee to deliver your products uniformly and with reliability in terms of material quality and other functional product features.

Internal production process

Our manufacturing facilities provide a wide range of services all under one roof. For your prototyping and product development cycles, there is no need to outsource any manufacturing or finishing services. Our 5-axis machining service can help you save costly breaks and reach the market faster than your competition.

Prompt delivery

Our efficient quality control, supply chain, and delivery logistics make it possible to deliver your prototypes and components as early as possible. We are dedicated to helping you evolve and create more number of parts in the least amount of time.

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