5Axis CNC Machining

Do you really understand 5-axis machining?

When it comes to 5-axis CNC machining, most people’s first impression is: high-level technology, high cost, and difficult operation. But is 5-axis machining really just that?Have you ever taken a closer look to unlock the secrets/performance characteristics of 5-axis machining—such as its advantages and disadvantages?

Advantages	Disadvantages
Reduces the number of setups, shortens process flow, lowers costs, and improves machining accuracy.	The machine structure is not ideal for heavy cutting (may need to work with 3-axis machines).
Allows shorter tool overhang, cuts beyond rotation center, and delivers excellent surface finish.	Processable workpiece size is relatively small compared to the machine footprint.
Enables machining of complex shapes with limited tool extension.	Machining accuracy is not always stable in all scenarios.
Supports 5-axis simultaneous interpolation for complex parts like impellers.	Higher processing cost.
	One surface often cannot be machined, requiring additional processes.

3-axis vs 5-axis Machining

What is 5-axis CNC machining? What is 3+2 machining?
What is the difference between a 3-axis machining center and a 5-axis machining center?
Anyone involved in designing or manufacturing mechanical parts has surely heard the term "5-axis" machining.
Here at Huazheng, we introduce you to "5-axis machining", one of the most advanced cutting technologies in modern manufacturing.

3-axis	5-axis
A typical machining center moves along only three linear axes: X, Y, and Z, which is why it is also called a "3-axis machining center".	5-axis machining refers to linear interpolation motion using any 5 of the coordinates X, Y, Z, A, B, and C.
What is 3+2 Machining?	During execution of a 3-axis milling program, the two rotary axes of the 5-axis machine are used to fix the cutting tool at a tilted position. This is where the name "3+2 machining" comes from. It is also called "positional 5-axis machining", because the 4th and 5th axes are only used to define the tool orientation at a fixed position, not continuously during machining. Essentially, 3+2 positional machining is the execution of 3-axis functionality at a specific angle (i.e., "position"). Put simply: once the machine is tilted to an angle, it machines in the same way as a conventional 3-axis machine.

3-axis

5-axis

A typical machining center moves along only three linear axes: X, Y, and Z, which is why it is also called a "3-axis machining center".

5-axis machining refers to linear interpolation motion using any 5 of the coordinates X, Y, Z, A, B, and C.

What is 3+2 Machining?

During execution of a 3-axis milling program, the two rotary axes of the 5-axis machine are used to fix the cutting tool at a tilted position. This is where the name "3+2 machining" comes from. It is also called "positional 5-axis machining", because the 4th and 5th axes are only used to define the tool orientation at a fixed position, not continuously during machining. Essentially, 3+2 positional machining is the execution of 3-axis functionality at a specific angle (i.e., "position"). Put simply: once the machine is tilted to an angle, it machines in the same way as a conventional 3-axis machine.

Currently, 5-axis CNC machine tools are available in the following configurations:

1. Double Swivel Head Type
Two rotary axes directly control the orientation of the tool axis.
2. Tilting Swivel Head Type
Two rotary axes are located at the spindle, but the rotary axes are not perpendicular to the linear axes.
3. Double Rotary Table Type
Two rotary axes directly control the spatial rotation of the workpiece.
4. Tilting Rotary Table Type
Two rotary axes are integrated into the worktable, but the rotary axes are not perpendicular to the linear axes.
5. Single Swivel Head & Single Rotary Table Type
One rotary axis acts on the tool, and the other acts on the workpiece.

3-axis Machining Center

According to ISO regulations, a left-hand rectangular coordinate system is used to describe the motion of CNC machine tools.The axis parallel to the spindle is defined as the Z-axis.The rotational axes about the X, Y, and Z axes are designated as A, B, and C respectively. Generally, 5-axis simultaneous machining refers to the linear interpolation motion of any 5 coordinates among X, Y, Z, A, and B.

Advantages of 5-Axis CNC Machining

Compared with 3-axis simultaneous CNC machining, 5-axis CNC machining offers the following advantages for complex curved surfaces from the perspectives of process planning and programming:

1. Cutting with the side edge of the tool, resulting in higher efficiency.
2. Reduced requirements for tooling and fixtures, enabling one-setup machining.
3. Elimination of special-purpose cutting tools, leading to lower costs.
4. Capability to use shorter cutting tools, improving machining performance and reducing costs.
5. Avoidance of zero cutting speed at the ball nose center, delivering higher efficiency and better surface finish.
6. Enables 5-axis multi-face machining in a single operation.
7.Suitable for machining 5-axis complex features such as pipe holes, corner cleaning, undercuts, and other irregular profiles.

5-axis Machining Center

The true value of a 5-axis machining center lies in 5-axis simultaneous machining, which enables synchronized and concurrent motion control of the three linear axes X, Y, Z and the two rotary axes A and C. This requires both the machine tool and the CAM system to support 5-axis simultaneous machining, and the creation of machining data is extremely challenging.Since both the table and the spindle are in dynamic motion, even a slight negligence in setup can result in an immediate collision between the spindle and the table.
To learn more professional knowledge about 5-axis machining, please contact us. We are here to solve your problems and concerns. Next time, shall we continue our discussion on true vs. false 5-axis machining?

Difficulties and Challenges of 5-axis CNC Technology

Next, let’s talk about the difficulties and challenges of 5-axis CNC technology:

1.5-axis CNC programming is abstract and difficult to operate.
2.NC program verification for 5-axis CNC is particularly critical.
3.Cutter radius compensation.
4.Post-processor.
5.Non-linear errors and singularity issues.
6.Requirements for CAD/CAM systems.
7.High investment required for machine tool acquisition.
8.The future intelligent trend of 5-axis machining tools.

Industry Machining Price Reference Table

Cost Item	Double Swivel Head Type	Tilting Swivel Head Type	Double Rotary Table Type	Tilting Table (Swing Type)	1 Swivel Head + 1 Rotary Table Type	3-Axis
Machine Hourly Rate (CNY/hour)	180~260	160~240	200~280	170~250	140~200	60~100
Number of Setups	1	1	1	1	1	4~5
Single Part Machining Time (h)	1.2~1.8	1.3~1.9	1.5~2.0	1.3~1.7	1.4~1.8	3.5~5.0
Direct Machining Cost (CNY)	216~468	208~456	300~560	221~425	196~360	210~500
Setup / Alignment Cost (CNY)	30~50 (1 time)	30~50 (1 time)	30~50 (1 time)	30~50 (1 time)	30~50 (1 time)	120~250 (4~5 times)
Tool Wear Cost (CNY)	40~70	40~70	60~90	40~70	40~70	80~120 (extended/break-prone tools)
Programming Cost (CNY)	120~180	130~190	100~150	100~150	90~140	50~80 (simple)
Pass Rate	95%~99%	93%~98%	94%~98%	96%~99%	94%~98%	65%~80%
Scrap Allocation Cost (CNY)	10~25	15~30	15~30	10~25	15~30	80~150
Total Cost per Part (CNY)	416~793	423~796	505~880	411~740	371~650	540~1100
Cost Ratio vs. Benchmark	1.2~1.3	1.2~1.3	1.4~1.5	1.1~1.2	1.0 (benchmark)	1.5~2.0
Key Cost Characteristics	High hour rate, high precision, low scrap rate	Medium-high hour rate, good for complex profiles	Highest hour rate, high load cost	Medium hour rate, highest precision	Best cost-performance, overall optimal	Low hour rate, but extremely high setup/scrap/time costs

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