Differences Between Linked 5-Axis Machining And 3+2-Axis Machining

What is 3+2-axis CNC machining?

Both vertical and horizontal milling machines can implement standard three machining axes. However, a turntable and tilt-rotation trunnions have been installed to provide rotational movement along the other two axes. Basically, this is a 3+2-axis machining process.

Positioning 5-axis machining describes this type of machining because the fourth and fifth axes are used to hold the component in place throughout the operation. Standard three-axis machining operations can then be performed as an alternative to the continuous motion required by the process. In addition, the cutting tools used in 3+2-axis machining centers are shorter and stronger. Therefore, you can be sure that the dimensional stability is improved.

The 3+2 machining arrangement enhances the advantages of standard 3-axis machining centers. The ability to machine 360 degrees around the workpiece is a major advantage. Therefore, less preparation is required throughout the production process. It will reduce manufacturing time and expense.

How does 3+2 axis CNC machining work?

In fact, the goal of 3+2 positioning CNC machining seems to be to achieve 3-axis machining at a given angle. This is the rationale behind this approach. In other words, even when turned to a specific angle, a CNC machine tool can continue to operate in the same manner as a standard three-axis machine tool.

What is linked 5-axis CNC machining?

Cutting tools can move in all directions simultaneously during synchronized 5-axis machining processes. The required parts are manufactured simultaneously from three linear axes and two rotary axes.

Simultaneous 5-axis CNC machining

The tilt table axis (A) and the rotary table axis (B) are the names of the two auxiliary axes. The movement of the axes indicates that 5-axis machining requires additional tilting of the tool spindle or table. As a result, more movement and rotation occurs, improving the performance of standard CNC machining programs.

With the help of fourth and fifth axes, machinists can create up to five different surfaces at a time. Therefore, the process is both accurate and productive. Additionally, it speeds up the process of creating intricate details and frames. Due to the reduced setup, this method is cost-effective and can be used in a wide range of experiments.

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3+2 and 5-axis CNC machining

Setup is where you'll see the biggest difference between 3+2 and 5-axis CNC machining. The cutting tools of a 5-axis machining center can move in five different directions. However, 3+2-axis machining combines the capabilities of a 3-axis CNC machine with that of a tilt-rotary trunnion and turntable.

The companies and product types best suited for 3+2 and 5+ axis machining also vary. 3+2 machining is effective for flat surface machining, while 5-axis CNC machining is ideal for machining complex-shaped surfaces. However, not all parts require full 5-axis, and sometimes 3+2 CNC machining seems more efficient. One of the significant advantages of five-axis machining is that it can complete CNC machining and geometric processing of a variety of parts, which is suitable for industries with higher requirements such as aerospace and military industry.

Which method should be chosen? You need to understand the pros and cons associated with each of them accordingly.

Advantages of 3+2 processing

The main advantages of 3+2 axis machining are:

Generate more complex features

This technique allows the use of shorter, harder cutting tools to create steep walls, cavity undercuts and many other complex features. In addition, specific angles to the cutting surface are possible.

Less programming code

Compared with simultaneous 5-axis machining, 3+2 CNC machining involves smaller spatial trajectories. The shorter the tool travel distance, the smaller the rotational motion, allowing freeform surfacing in more accessible programming.

Lower costs and shorter cycle times

3+2 CNC machining is capable of machining five or more different surfaces simultaneously, which can be a huge challenge for traditional three-axis machining centers.

Disadvantages of 3+2 processing

3+2 machining is usually thought of as setting a constant angle to the spindle. Components with complex geometries may require many titled views to cover the entire surface, but this results in overlapping tool paths, which increases machining time.

Advantages of 5-axis machining

Save cost and time

5-axis machined parts can be mass produced in a single operation. A single setup helps save time and money. Additionally, using shorter molds extends service life and eliminates the need for frequent maintenance and regular mold replacement, further reducing production costs and cycle times.

Excellent quality and precision

The latest 5-axis CNC machine tools on the market do not need to adjust various angles of the workpiece when cutting, greatly improving the processing tolerance. This means 5-axis machining involves less human interference, so there is less opportunity for errors while improving part quality.

complex geometric details

5-axis machining centers allow tools to access parts from any direction. Workpieces can be finished individually on this machine, eliminating the need to move them through multiple workstations. Allowing not only movement on the X, Y and Z linear axes, but also rotation on the A and B axes, the additional rotations in this machining method allow for more complex geometries and shapes.

Improve productivity and repeatability

When using 5-axis machining, the cutting tool is often tangential to the cutting surface. This configuration enables additional material to be removed as the tool rotates. As a result, overall machining costs and cycle times are reduced. Additionally, certain machine settings allow the use of shorter cutting tools, increasing tool life and ensuring repeatability.

Excellent surface treatment

The additional axis aligns the workpieces correctly, bringing them closer to the cutting tool. Therefore, you can use shorter ones to create the desired shape. These tools allow for high-speed cutting with minimal vibration. Less vibration reduces the appearance of "jitter" marks on the final product. You can expect to create an outstanding surface finish while reducing the expense and time of post-processing.

Disadvantages of 5-axis machining

It pays to understand the disadvantages of 5-axis CNC machining, despite its many benefits.

Higher requirements for programming and operation

The additional axes of rotation and the spatial trajectories involved are specialized and abstract. Therefore, more programming effort is required to achieve the necessary machining precision, accuracy and surface quality.

Higher initial cost

The prices for 5-axis CNC machines and their necessary software are quite high. Much higher than the requirements of 3-axis or 4-axis machining centers. Likewise, machines are more expensive and complex to maintain than traditional machine tools. This factor also directly affects the processing cost of 5-axis machined parts.

Doesn't work with some apps

4- and 5-axis machining technologies cannot be used when the tool is too short or the handle is too wide. Therefore, vibration cannot be avoided at tilt angles.

Which is better, 3+2 or 5-axis milling?

You will find that the capabilities of 5-axis and 3+2 machining are very similar. Both can help any factory's production line run more efficiently. However, the appropriate approach will depend on the specific application for which the results are expected. Specific to flat processing projects, 3+2 processing is very effective. In contrast, 5-axis machining is more suitable for complex contoured surfaces.

With 3+2 machining, current 3-axis machining users can quickly upgrade to a full 5-axis machining operation. It offers many of the high-end features of a full 5-axis machine without the high price tag. Since 5-axis machines are expensive to set up and program, 3+2 machining may be a better option.

On the other hand, 5-axis machining centers increase productivity while manufacturing components with complex geometries and tight tolerance standards. They often increase the efficiency and profitability of a wide range of processing tasks. As a result, less time is spent on setup, the finished product is more precise, and production time is reduced because they can process all five sides of the component simultaneously.