3 Axis CNC Machining vs. 5 Axis CNC Machining: Which One is Better for Your Project
The advent of CNC has made modern manufacturing easier. It is accurate, versatile, and comes in various types to meet different industries’ needs. 3-axis and 5-axis CNC are two common types with unique advantages, disadvantages, and applications. Though they have similar end goals, they are not the same.
Are you struggling to decide between 3-axis and 5-axis CNC machining? This article will explain how each operates, their advantages and disadvantages. Read on to find out the difference comparing 5 axis vs 3 axis CNC and when to use the different techniques.
3 axis vs 5 axis CNC machining
Understanding Computer Numerical Control (CNC)
CNC involves the computerized operation of tools and machinery. The whole process is automated and gives no room for errors. With CNC, the first step is to convert the 2D or CAD design of the final part to a language that the machine understands in the form of G-code and M-code for CNC with CAM software.
These programming languages control the movement of the cutting tools to produce accurate parts. Then the machines execute the CNC codes and start machining. CNC can control almost any type of tool from mills and lathes to laser and waterjet cutters.
What is 3-Axis CNC
The 3-axis is one of the simplest forms of CNC machining. It involves the coordinated movement of the cutting tools along three linear axes; X, Y, and Z. X represents horizontal side-by-side movement while the Y axis moves forward and backward. The last Z axis is the vertical up and down movement.
All three axes move simultaneously to machine 2D and 2.5D geometry. You can use a 3-axis CNC machining for many tasks including milling slots, drilling holes, and cutting sharp edges. It accurately crafts mechanical parts and functional components from raw materials.
Pros and Cons of 3-Axis CNC
3-axis CNC offers you unlimited benefits in manufacturing. The following are some pros of 3-axis machining
Accuracy
With a 3-axis CNC, you can produce dimensionally accurate parts all the time. It cuts the components exactly to specification without errors. 3-axis CNC has a tolerance level of about 0.001mm which ensures optimal performance of the final parts. Furthermore, this process is repeatable and manufactures components that closely resemble each other.
Versatility
You can machine different engineering materials with a 3-axis CNC. The most common are metals such as aluminum, titanium, stainless steel, and brass. You can also safely work with plastics, polymers, wood, and composites. However, note that you have to optimize the different CNC machining parameters for the various materials to get the best results.
Easy to Operate
You will find 3-axis machining easy to use and operate. The machine is simple to set up and you don’t have to be highly trained. However, experience and expertise will help in maximizing its use. Furthermore, 3-axis CNC has the simplest programming. Even novices and beginners can easily navigate their way through.
Cost Effective
The upfront cost of 3-axis CNC is relatively low. If you run a small business or are on a tight budget, this machine might be perfect for you. The cost of maintaining 3-axis machines is also low. They are smaller and come with fewer movable parts. For this reason, it is easy to maintain them to prevent wear and tear.
Despite the numerous benefits of using 3-axis machining, it also comes with some limitations. The following are some shortcomings of 3-axis CNC you should be aware of
Limited Functionality
3-axis CNC comes with reduced freedom of movement as the tools can only move in three directions. This feature makes it challenging to machine complex shapes and parts with intricate designs. It doesn’t automatically rotate the workpiece and necessitates multiple setups to machine different sides of the part.
Limited Surface Finish
The surface finish of the final part is also a limitation. When compared to advanced multi-axis machining, the surface finish 3-axis CNC produces is rougher. It leaves visible tool marks because the tools are longer.
What are the Applications of a 3-axis CNC Machining?
The 3-axis CNC machining machine is used in many industrial applications. The following are some common ones
Automotive Industry
The 3-axis CNC machining is revolutionizing the automotive industry. It can meet all your prototyping and part production needs efficiently. Furthermore, this machine is ideal for customization and one-off manufacturing of automotive parts. You can use a 3-axis CNC machining to make critical components such as cylinder heads, chassis, transmission systems, and interior panels.
Medical Industry
The medical industry has high standards and strict requirements, and this machine meets them excellently well. It’s a good fit to produce everything from surgical instruments to prosthetics. Also, it’s capable of manufacturing diagnostic equipment and dental tools.
Mold and Die Making
They produce high-quality molds that you can further use to manufacture strong and repeatable castings. The CNC-machined molds have accurate dimensions and a good surface finish. Additionally, you can easily work on customized mold designs.
Electronic Industry
Many electrical and electronic components are CNC-machined products. This machine can process both metallic and nonmetallic materials used in the electronic industry. It allows for quick production of enclosures, heat sinks, and cooling systems.
Aerospace Industry
3-axis CNC machining is suitable for creating and assembling aerospace components. It is possible to produce multiple aerospace parts with tight tolerance. You can create lightweight yet robust structures that increase fuel efficiency. Some common examples of 3-axis CNC machined aircraft parts include shafts, engine components, landing gears, and fuselage.
Jewelry Industry
The popularity of 3-axis CNC machining is increasing in jewelry manufacturing. They allow for precise shaping and engraving of logos, texts, and symbols on special metals. The precision of 3-axis machining machines makes them ideal for detailed and delicate jobs. You can use these machines to make new designs in a short time frame.
What is 5-Axis CNC
5-axis CNC is one of the most sophisticated multi-axis machining types. It gives the cutting tools a multidirectional approach and machines a workpiece from five different sides. In addition to the basic linear axes X, Y, and Z, the tools also move along rotational axes. Typically, a 5-axis CNC machine uses either the A/C or B/C axes. A signifies rotation along the X axis, B is the movement around the Y axis, while C rotates along the Z axis. With a 5-axis CNC, you can work on a part in all directions in a single setup.
Note that 5-axis CNC is not the same as 3+2-axis CNC. The major difference is in their setup and tool orientation. While the movement in the 5-axis CNC is simultaneous, the rotational and linear axes on the 3+2-axis CNC move sequentially. 5-axis CNC machining is ideal for complex applications. It is accurate, repeatable, and speeds up machining operations.
Pros and Cons of 5-Axis CNC
The use of 5-axis CNC has revolutionized modern manufacturing. It is ideal for many applications across different sectors. Here are some major benefits you will get from using 5-axis CNC for your project.
Machine Complex Shapes
5-axis CNC can produce various shapes that would have been different with 3 or 4-axis machining. It is possible to maneuver the tools to move in different directions so you can machine intricate designs and features. 5-axis CNC machining works on parts with irregular shapes and box and disc-shaped parts with ease.
High Accuracy and Precision
The accuracy of the 5-axis CNC is second to none. You can work on a workpiece in one operation. Multiple setups and repositioning at different angles are potential sources of errors and mistakes. Furthermore, it is possible to use shorter tools in 5-axis CNC. Shorter tools are more rigid and less likely to deflect.
Quality Surface Finish
5-axis CNC creates a smoother and more glossy surface finish. The reason behind this is the two extra rotational axes. They bring the workpiece closer to the cutting tools and reduce the incidence of surface flaws and errors. A high-quality surface finish improves the performance and longevity of the final part.
High Productivity
5-axis CNC increases efficiency in manufacturing. It is fast and reduces machining time. 5-axis CNC machines can run unattended to give you more time to focus on other important areas. Furthermore, it produces less material waste and scrap rate.
5-axis CNC also has few limitations. Some of the disadvantages of 5-axis CNC include
High Cost
The cost of purchasing and running a 5-axis CNC is considerably high. It requires more complex software to function which further adds to costs. Furthermore, its maintenance requirements are higher than that of 3-axis CNC. The machines it operates are larger and take time to calibrate during routine maintenance.
High Technical Requirements for Operators
Highly skilled is required to make the most of 5-axis CNC. The additional two axes make it more complex and difficult to program. It requires advanced mathematical and technical skills to run smoothly without collision. This increases labor costs and overall machining expenses.
What are the Applications of 5-axis CNC Machining?
Aerospace Industry
5-axis machining can precisely produce complex blade profiles, Aircraft Structural Components such as fuselage skins, and structural frames, and Critical parts such as turbine disks, casings, and combustion chambers, ensuring optimal performance and efficiency.
Automotive Industry
The automotive industry relies on 5-axis CNC machining to create complex injection molds, die-casting molds, automotive Components: Such as engine blocks and transmission housings
Medical Industry
5-axis CNC machining makes components like artificial bones, CT scanner parts, molds for medical equipment.
3 Axis CNC vs 5 Axis CNC: What are the Differences?
Though 3-axis CNC and 5-axis CNC use the same technology, they are different in many ways. The table below will explain the differences between both techniques. You can use it as a guide to decide on the best for your project.
| Parameters | 3-axis CNC | 5-axis CNC |
| Movement Capability | 3-axis CNC has a limited degree of cutting tool movement. It can only move along linear axes; X, Y, and Z. | 5-axis CNC moves the tool along linear axes (X, Y, and Z) and rotational axes (A and B). |
| Complexity of Parts | 3-axis CNC is ideal for simple shapes and straightforward designs. | You can use this type to machine complex parts because the tools can get to hard-to-reach areas. |
| Surface Finish | It produces a rough surface finish that often requires secondary finishing. | 5-axis CNC gives a smooth finish because the cutting tools are closer to the workpiece. |
| Set up and Cycle Time | It comes with more time for setup and slower cycle time. | It is faster with less time for set up. |
| Accuracy | 3-axis CNC is accurate and precise | 5-axis CNC has the highest accuracy and produces repeatable parts. |
| Cost | 3-axis CNC is relatively affordable. | The upfront costs, maintenance requirements, and labor costs are considerably higher. |
| Programming | It requires simple programs to control the movement of cutting tools. | 5-axis CNC needs a more complex program and software to maximize its full benefits. |
| Tool Breakage | 3-axis CNC comes with a higher risk of tool breakage. The tool approaches the workpiece perpendicularly and can easily deflect. | Tool breakage is less frequent with 5-axis CNC. Shorter tools improve rigidity and reduce vibrations. |
| Error Accumulation | There is a tendency for error accumulation in 3-axis CNC because of the multiple setups. | 5 axis requires a single up with a reduced risk of accumulation of errors. |
| Applications | 3-axis CNC is ideal for less complex projects and manufacturing of simple components like fittings, plates, and brackets. | You can use 5-axis CNC for parts with intricate shapes and contoured edges in the automotive, aerospace, and medical industries. |
3 Axis CNC vs 5 Axis CNC: Which One is Better?
None is considered better between 3-axis CNC and 5-axis CNC. The one you go for depends on your budget and production goals.
When to Use 3-Axis CNC
Go for 3-axis CNC when machining simple parts with no complex features. It is ideal for low-volume production because of the longer setup and machining time. Furthermore, 3-axis machining should be the go-to technique when you are on a tight budget.
When to Use 5-Axis CNC
5-axis CNC is suitable for applications with tight tolerance requirements. You should use it when machining complex-shaped parts in high volume. Additionally, this technique is a good fit for components with intricate features on all sides.
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Conclusion
When comparing 3-axis Vs 5-axis CNC, no one is considered better. There is no standard way to choose the best for your project as there are some factors to consider. You need to consider your production requirements, production goals, volume of production, available level of expertise and expertise, and your budget. This article has explained what 3-axis and 5-axis CNC are, their differences, and when to use the different techniques.
FAQS
What can a 5-axis CNC do?
A 5-axis CNC is capable of crafting intricate shapes that involve various angles and curves. By maneuvering the cutting tool along five different axes, it achieves enhanced surface smoothness and greater precision in the produced components. Additionally, this type of CNC machine excels in continuous milling, allowing the cutting tool to seamlessly trace the material’s curves, resulting in fewer imperfections and steps in the finished product.
Is the 3-axis CNC a good starter investment than the 5-axis CNC?
Absolutely! The cost of purchasing and maintaining 3-axis CNC is cheaper than that of 5-axis CNC thus, making it a good starting investment.
What are the main industries that use 3-axis and 5-axis CNC machines?
The usage of the two machines cut across numerous industries but the major ones are healthcare, aerospace, manufacturing, and automotive.
Is it possible to upgrade a 3-axis CNC machine to a 5-axis?
Although upgrading a 3-axis CNC machine to a 5-axis CNC machine is possible, the downside is the complexity and the huge amount of money required.
Though two additional rotary axes have been added, these axes are primarily used to fix the workpiece at a specific angle. The machine then performs 3-axis cutting. Therefore, it cannot adjust the angle of the tool and workpiece in real-time during the machining process like a 5-axis machining. As a result, it has poorer flexibility in machining complex curved surfaces and multi-angle features.
Therefore, it is advisable to buy a 5-axis CNC machine if it is a production requirement.
