Why do we need to use five axes? What parts are suitable for five axis CNC machining?

Engineers often ask if it is possible to directly use five axis CNC machining when they send a 3D drawing with free-form surfaces? Will the price be much higher? Five axis machining can indeed solve many problems that three axes cannot achieve, but  all parts are worth five axes. The structural components that are truly suitable for five axis CNC machining are those with high precision requirements for curved surfaces, deep cavities, oblique holes,  multi-faceted surfaces. Shenzhen Huiwen Zhizao has been deeply engaged in precision machining of robot components for many years, with its own CNC machining centers covering three, four,  five axes. This article will explain  the perspectives of component types  cost structure.

1、 Core differences between five axis CNC machining  three-axis machining

Ordinary three-axis machining can only achieve linear motion in X, Y,  Z directions. If the part has side slanted holes  back features, it must be flipped over, re clamped,  aligned. The more times the clamping is replaced, the higher the probability of benchmark deviation,  precision components are prone to irreversible cumulative positioning errors.

Five axis CNC machining adds two sets of rotation axes on top of the three-axis foundation, allowing the tool to approach the workpiece  multiple angles. A large number of curved surfaces, deep cavities,  inclined holes can be clamped  formed in one go. The core advantage of five axis CNC machining is  only the higher equipment parameters, but also the reduction of repeated clamping  positioning deviation, achieving complex structural machining that is difficult to complete with three axes. Although many CNC processing plants are equipped with five axis equipment, they lack corresponding process accumulation. Even if the hardware is in place, it is difficult to stabilize  meet the dimensional  positional tolerances of complex precision components.

2、 Typical precision components suitable for five axis CNC machining

The following types of precision components can be fully utilized by using five axis CNC machining, which is also a high-frequency order type that many reliable CNC machining factories can undertake:

1. Impeller  turbine components: The blades are continuous free-form surfaces that must be formed in one go through multi axis linkage, making it difficult to achieve complete surface machining with three axes.

2. Precision components of medical equipment: titanium alloy bone plates, medical joint parts, materials that are difficult to cut  require high multi-faceted fit. Five axis CNC machining reduces the risk of multiple clamping.

3. Robot precision structural components: humanoid robot joint shell, dexterous hand shell, a large number of inclined installation holes, arc-shaped weight reduction grooves, strict requirements for position  coaxiality, are typical application scenarios for five axis CNC machining.

4. High end automotive shell  bracket components: The shell  power peripheral bracket are densely covered with inclined holes  deep cavities,  multiple flipping of the three axes can easily result in cumulative errors. Five axis CNC machining is used to ensure the relative positional accuracy of multi-faceted features.

5. Frame  bracket in consumer electronics  smart hardware: The appearance  assembly surfaces are staggered, with high requirements for dimensional consistency. One clamping molding avoids deviations caused by multiple positioning.

Of course, if it is only parts with simple structures  few characteristic surfaces such as regular plates, simple shells,  ordinary brackets, three-axis machining will be more cost-effective. To determine whether to perform five axis CNC machining, it is  enough to simply look at the number of surface surfaces of the parts. The key is to consider the structural features  tolerance conditions,  whether multi axis linkage is needed to ensure the comprehensive quality of precision components.

In the automotive industry, five axis CNC machining is commonly used for precision components around shells, brackets,  powertrains. These types of parts are densely packed with inclined holes  deep cavities,  undergo three-axis repeated flipping processing, making it difficult to control benchmark errors; Titanium alloy joint  bone plate materials in the medical device field are difficult to cut,  five axis CNC machining reduces the clamping process, resulting in integrated molding of curved surfaces  assembly surfaces; The joint shell in the field of robotics is a typical five axis machining workpiece that has been verified by many CNC machining factories. These industry scenarios share a common pattern: the more complex the part structure  the more clamping times, the higher the requirement for positional accuracy,  the more prominent the process value of five axis CNC machining.

3、 What are the main cost differences in the quotation for five axis CNC machining

Many customers compare multiple CNC machining plants  find that the quotation for five axis CNC machining is generally higher than that for three-axis machining,  the cost difference mainly comes  four aspects:

1. Equipment investment cost: The procurement  depreciation cost of five axis equipment is much higher than that of three-axis machine tools,  the equipment cost is amortized  the quotation of precision components based on the processing hours.

2. Programming simulation cost: Complex curved parts require specialized CAM programming  collision simulation verification, with a much longer programming  trial cutting cycle than ordinary three-axis parts, extending the overall delivery time.

3. Actual machining hours: The five axis linkage cutting strategy is more complex,  some feature cutting takes longer, requiring specialized optimization of material removal strategies.

4. Cost of testing  verification: For complex curved surface precision components, key dimensions require the use of coordinate measuring equipment for testing, which incurs corresponding labor costs for testing  issuing reports.

So when comparing quotes, we cannot just look at the hourly unit price of the machine tool. Programming, tooling clamping, testing,  issuing reports all need to be included in the calculation. The smaller the batch size of the order, the higher the allocation of fixed costs such as programming  first article inspection to a single precision component.

For example, a precision impeller component with a free-form surface requires multiple flipping processes for the three-axis scheme,  some surfaces also need to be manually trimmed, resulting in high processing risks; Using five axis CNC machining, the initial programming  simulation take a long time, but the machining can be completed in one clamping, ensuring the continuity  consistency of the surface  dimensions. If we only compare the unit price of the machine, five axis CNC machining may seem more expensive, but taking  account the implicit costs of rework, manual repair, assembly  debugging, the overall cost may  be higher. This is also an important reason why more  more complex parts customers are willing to seek CNC machining plants with mature processes for five axis CNC machining.

Shenzhen Huiwen Intelligent Manufacturing Technology Co., Ltd., as a professional CNC processing factory, undertakes various five axis CNC processing businesses. For precision components of robots, medical equipment,  automation equipment, DFM process evaluation can be conducted based on drawings to objectively evaluate whether the part is suitable for three-axis  five axis solutions. We will  blindly recommend high priced five axis processes; At the same time, equipped with Zeiss coordinate detection equipment, complete full-size inspection of key components, provide formal inspection reports as needed,  meet the needs of prototype sampling  small to medium batch production.

4、 Practical judgment process: Should your parts be machined with five axis CNC

After receiving the drawings, you can conduct a self-assessment according to this process  then contact the CNC processing factory to conduct a five axis CNC processing inquiry:

1. Check the structure of the parts: whether the drawing contains complex free-form surfaces, deep cavity reverse buckles, multi angle oblique holes,  whether there are features that require the same reference to ensure positional accuracy;

2. Check the benchmark conditions: if three-axis machining is used, can the positioning fixture meet the drawing tolerance after multiple flipping  clamping,  will repeated clamping cause error control;

3. Check order batch: During the prototype  small batch trial production stages, using five axis CNC machining for complex parts can reduce repeated trial  error; For large batch orders, it is necessary to evaluate both the mass production process  the overall cost simultaneously;

4. Comprehensive evaluation budget: When inquiring, the CNC processing factory is required to include programming, tooling, testing,  reporting in the quotation, rather than just looking at the unit price of individual processing.

5、 Frequently Asked Questions  Answers

Q: Does the precision of five axis CNC machined parts necessarily mean higher accuracy?

A:  necessarily. The core value of five axis CNC machining is to reduce the cumulative error caused by multiple clamping; The final product accuracy also depends on the machine tool status, programming tool path, tool selection,  inspection control. Similarly, for five axis equipment, different CNC processing plants have different technological processes, resulting in significant differences in the quality of precision components produced.

Q: Would it be better to hand over simple parts to five axis CNC machining?

A:  recommended. Simple parts such as tablets  simple straight hole brackets have higher cost-effectiveness when processed with three-axis machining, while being processed with five axis CNC will only increase manufacturing costs  will  bring quality improvement.

Q: What information is required for the drawings of a CNC machining factory to do five axis CNC machining?

A: Complete 3D model STEP/IGES files  2D engineering PDF drawings, clearly marked with tolerances, roughness, materials, surface treatment,  inspection report requirements, to facilitate the evaluation of CNC processing plants  output reasonable five axis CNC processing plans  quotations.

Q: What five axis CNC machining precision components can Huiwen Zhizao undertake?

A: Shenzhen Huiwen Zhizao can undertake precision components such as humanoid robot joint shells  dexterous hand parts, support DFM drawing review, prototype sampling to small  medium-sized batch delivery, own five axis  three-axis equipment,  do  subcontract to external parties.

Summary

In summary, five axis CNC machining is  omnipotent. It is more suitable for precision components with complex surfaces, deep cavity inversion, multi angle oblique holes,  strict requirements for multi-faceted positional accuracy; Simple structured ordinary parts, three-axis machining has better cost advantages. Shenzhen Huiwen Zhizao has been deeply engaged in precision machining of robot components for many years. It is a hardware full chain service provider for high-end robots, focusing on robot mechanical design, core component manufacturing,  integrated hardware services for assembly. Equipped with three-axis, 3+2 positioning, five axis linkage  other processing capabilities, matched with Zeiss three coordinate inspection, one-stop landing  DFM drawing review, prototype sampling to small  medium-sized batch delivery. Welcome to provide drawing consultation. We can provide 2D drawings, 3D models,  technical requirements to obtain DFM process evaluation  itemized quotations.