In the sprawling arena of manufacturing and engineering, one technology that is rewriting the rules is 3-axis machining. But what exactly is this wonder of modern engineering? Dive in as we unravel the intricacies of this innovative technology.
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Fundamentally, 3-axis machining is a multi-axis machining process that involves the coordinated movement of a machine’s cutting tool or a workpiece along three distinct axes simultaneously. This simultaneous operation along the x-axis, y-axis, and z-axis underpins the principle of this machining process.
When employed in CNC machining, this ensures high precision in material removal, leading to the creation of accurately detailed and intricate mechanical components.
This section delves into the complex but fascinating process of 3-axis machining.
In 3-axis machining, the cutting tool moves along the three axes – X, Y, and Z.
The X and Y axes represent the horizontal plane, while the Z axis signifies vertical movement.
The combined motion in these three axes allows the CNC machine to accurately and efficiently remove material from the workpiece, giving it a desired shape.
CNC machines play an essential role in 3-axis machining. These machines, equipped with automated cutting tools, are capable of executing complex machining operations with high accuracy and speed.
Additionally, the CNC milling machine’s spindle’s rotation enhances the cutting tool’s ability to create precise geometric shapes.
A key component of the 3-axis machining process is the milling machine. It is this machine’s extraordinary precision and range of movement that enable it to craft complex geometries from raw materials. The greater accuracy of these machines ensures that even the most intricate mechanical components can be machined to exact specifications.
When it comes to 3-axis machining, the kind of CNC machine used is critical. For instance, a 3-axis CNC machine is ideal for tasks that involve material removal in three planes.
On the other hand, a 5-axis CNC machine offers even more capabilities, including the ability to rotate the cutting tool or workpiece around additional axes (the A and B axes), thereby enabling machining of more complex parts.
3-axis machining’s exceptional accuracy and versatility make it suitable for a wide array of applications. Industries ranging from automotive to aerospace, from medical to energy, employ 3-axis machining to produce complex parts.
Additionally, the technology is also extensively used for drilling, milling, and tapping operations. It’s worth noting that 3-axis machining’s advantages may not always outweigh its cost and setup time, depending on the application’s complexity.
The benefits of 3-axis machining are manifold. Here are a few that stand out:
While 3-axis machining offers numerous advantages, it is not without its limitations:
The main difference between 3-axis and 5-axis machining lies in the number of directions in which the cutting tool or workpiece can move. In 3-axis machining, movement is limited to the X, Y, and Z axes.
On the other hand, in 5-axis machining, two additional axes, typically referred to as the A and B axes, allow for rotations around the X and Y axes, respectively. This greater movement capability allows for more complex shapes and geometries to be machined, and for parts with undercuts or pockets to be processed in a single setup.
However, this comes at a cost. 5-axis CNC machines are significantly more expensive than 3-axis CNC machines. Additionally, they may require more extensive operator training, which can increase the overall operational costs.
3-axis machining stands as an impressive testament to technological innovation in the field of manufacturing and engineering. Its capabilities in producing precise, high-quality mechanical components have made it a go-to resource for various industries. Yet, like all technologies, it comes with its limitations, mainly when tasked with complex geometries or higher processing requirements.
While its benefits are manifold, it’s important to weigh these against its cost and setup time, particularly when considering more complex tasks that might be better suited to 5-axis machining. With a clear understanding of what 3-axis machining offers and its limitations, manufacturers can make informed decisions about which process best suits their needs.
We hope this article has provided you with a thorough understanding of 3-axis machining. For more in-depth knowledge and insights into the world of machining, subscribe to our content, or feel free to visit us to learn more about our wide range of machining solutions and services.
At CloudNC, we have a range of state of the art 3-axis, 4-axis and 5-axis milling machines. As a designer, having an understanding of which type of machine your part will be manufactured on is critical in optimising your design. When designing a CNC machined part, you might not have thought about which type of machine your part will be machined on, but the complexity and type of geometry you can design will be different for different types of machines.
The main difference between 3-axis, 4-axis and 5-axis machining is the complexity of the movement both the workpiece and the cutting tool can move through, relative to each other. The more complex the motion of the two parts, the more complex the geometry of the final machined part can be.
The most simple type of machining, where the workpiece is fixed in a single position. Movement of the spindle is available in the X, Y and Z linear directions.
3-axis machining
3-axis machines are typically used for machining of 2D and 2.5D geometry. Machining of all 6 sides of a part is possible in 3-axis machining but a new fixturing set-up is required for each side, which could be expensive (more on that below). For a single fixture setup, only one side of the part can be machined.
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A unique setup is required for each side of a part
Many complex and practical shapes can be manufactured by 3-axis CNC milling, especially when in the hands of a world-class CNC machining facility. 3-axis machining is best suited to manufacture of planar milled profiles, drillings and threaded holes in-line with an axis. Undercut features are possible with the use of T-slot cutters and Dovetail milling cutters.
However, sometimes the designed feature physically cannot be manufactured by a 3-axis machine, or the feature might be more economically viable to machine with a 4 or 5-axis machine.
Features not possible in 3-axis milling include any features on an angle to the X-Y-Z co-ordinate system, even if the feature itself is planar. There are two types of angled features you can design, and understanding the distinction between them is important when designing parts for CNC milling.
ANGLED FEATURE
This is a feature machined on an angle to one of the X, Y or Z axes. For example, the planar milled surface below is at 45° to the X-axis e.g. a rotation of the A-axis.
Milled feature angled in a single plane at 45°
COMPOUND ANGLE FEATURE
This is a feature machined on an angle to two axes. For example the planar milled surface below is machined at a 45° angle to the X-axis, and a 30° angle to the Z axis.
Both angled and compound angle features cannot be machined by 3-axis CNC machines.
This adds a rotation about the X-axis, called the A-axis. The spindle has 3 linear axes of movement (X-Y-Z), like in 3-axis machining, plus the A-axis occurs by rotation of the workpiece. There are a few different arrangements for 4 axis machines, but typically they are of the ‘vertical machining’ type, where the spindle rotates about the Z axis. The workpiece is mounted in the X-axis and can rotate with the fixture in the A-axis. For a single fixture setup, 4 sides of the part can be machined.
4-axis machining can be used as a more economically viable way of machining parts theoretically possible on a 3-axis machine. As an example, for a part we recently machined we found that using a 3-axis machine would have required two unique fixtures at a cost of £ and £800 respectively. By utilising the A-axis capability of 4-axis machining, only one fixture was required at a cost of £. This also eliminated the need for fixture change-overs, reducing costs even further. Eliminating the risk of human error meant we machined the part to a high quality with no need for expensive Quality Assurance investigations. Removing the need to change fixtures has the additional benefit that tighter tolerances can be held between features on different sides of the part. Loss of accuracy due to fixturing and re-setup has been removed.
Complex profiles such as cam lobes can be machined on a 4-axis machine
There are two types of 4-axis CNC machining: indexing and continuous.
Index 4-axis CNC machining is when the 4th axis (A-axis) rotates whilst the machine is not cutting material. Once the correct rotation is selected, a brake is applied and the machine resumes cutting.
In continuous 4-axis machining, the machine can cut material at the same time as the A-axis rotation, simultaneously. This allows complex arcs to be machined, such as the profile of cam lobes, and helixes.
4-axis machining gives us the ability to machine angled features, otherwise not possible with a 3-axis machine. Bear in mind that 4-axis machining allows a single axis of rotation per fixture setup, so all angled features must be angled about the same axes, or additional fixtures put in place.
Helical machining possible with 4-axis machines
These CNC milling machines utilise 2 of the 3 possible rotation axis, depending on the type of machine. A machine will either utilise a rotation in the A-axis and C-axis, or a rotation in the B-axis and C-axis. The rotation either occurs by the workpiece, or by the spindle.
There are two main types of 5-axis CNC machines: 3+2 machines, and fully continuous 5-axis machines.
In 3+2 axis machining two rotational axes operate independently to each other, meaning that the workpiece can be rotated to any compound angle in relation to the cutting tool for features to be machined. However, two axes rotation at the same time as machining is not possible. 3+2 machining can produce highly complex 3D shapes. Fully continuous 5-axis machining can simultaneously rotate the two rotation axis, at the same time as machining and the cutting tool moving linearly in XYZ co-ordinates.
5-axis machining
Continuous 5-axis machining can produce highly complex 3D shapes, not only planar compound angled features but complex curved 3D surfaces, giving us the ability to produce parts normally reserved for moulding processes.
5-axis machining gives designers a huge level of flexibility to design very complex 3D geometry. Understanding the possibilities of each type of CNC machining is essential in design of CNC machined parts. If your design needs the use of a 5-axis CNC, make the most of it! Which other features could benefit from the capabilities of 5-axis machining?
At CloudNC, we’re working on software to make machining simpler – automating large parts of the journey and helping people with less experience use CNC machines like an expert can. If you’d like to know more, why not check out our technology to view our CAM Assist solution, watch a video about where we think our solutions can take us, ur mission and vision, or take a look at our careers page!