Producing industrial parts requires accuracy, safety, and cost-saving efficiency. Most industries start with manual machining, but it is an old-fashioned manufacturing method. This process leaves room for error, operator accidents, and product inconsistencies. Thankfully, there are many different types of CNC machines that provide the answer to this problem.
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CNC (Computer Numerical Control) machining is a common manufacturing process that uses pre-programmed computer software to operate factory tools and machinery. CNC machines are responsible for making parts in almost every industry throughout the world. They create products and components out of aluminum, plastics, wood, and other hard materials.
There is more than one type of CNC machine, and each one serves a specific purpose in parts manufacturing. This guide will discuss various CNC machining methods, including the top-tier 6-axis CNC machine.
Automated motion control machines utilize three components:
CNC machining is a process that uses a computer-driven machine tool to transform a piece of solid raw material into a different shape. This process depends on digital instructions made on CAM (Computer Aided Manufacturing) or CAD (Computer-Aided Design) software capable of writing G-code. These codes have numerical values that the CNC machine&#;s controller can read to execute the process from beginning to end.
Once the computer on the controller interprets the design, it moves either the cutting tool or workpiece on multiple axes to cut the desired shape into the raw material. It exceeds the limitations of manual operator controls that require a live worker to press buttons or move levers. The machine knows what to do by reading specific machining commands.
Automated manufacturing allows industries to create parts quickly and precisely, but not all components are created equal. The type of CNC machine needed to make the final product depends on the part&#;s dimensions and geometric patterns.
CNC machines are typically divided into these five groups:
The axes determine the machine&#;s abilities, including how it moves, how it cuts into the workpiece, and whether or not it maneuvers the material or cutting tool to create the finished product.
For example, 3-axis machining keeps the workpiece in a stationary position while the cutting tool moves on an XYZ plane to trim away unnecessary material. It is ideal for milling slots, cutting sharp edges, and drilling holes in mechanical components.
This commonplace CNC machine includes built-in rotary cutting tools to drill and cut raw materials. The process begins by placing a metal, wood, or plastic block inside the machine. Next, the computer tells the machine how to cut or drill into the material.
CNC milling machines are ideal for making notches, grooves, shapes, and pockets. They are available primarily as 3-axis machines, but they can go up to 6-axis.
This machinery also cuts materials, but it uses a computer to maneuver a high-powered torch, instead of a rotary tool, to cut into 2D metal sheets or wood. The torch is strong enough to quickly burn through dense metal, with temperatures reaching almost 50,000 degrees Fahrenheit.
Manufacturers commonly use CNC plasma cutting in welding centers, auto repair shops, and industrial construction centers.
Lathe machines move the raw material on a spindle instead of maneuvering a cutter or torch, and these devices use fewer axes than milling machines. CNC lathe machinery has a lathe in the center that rotates and manipulates the material to form the required shape. The computer controls the positioning of the material.
CNC lathes are used in industries like automotive, aerospace, and firearm manufacturing.
For rigid materials, the CNC laser cutting machine is an ideal choice. The powerful laser provides increased accuracy, and it can cut custom designs and shapes into the raw material. Its operation is similar to plasma cutters, but it can also cut plastic with precision.
CNC grinding machines use a stationary wheel to cut into a workpiece. These systems are available up to 5-axis, and they work with high-pressure coolants to quickly remove metal pieces from the part without burning the equipment.
Manufacturers use grinders for grinding milling cutters, surface grinding, contour grinding, and flute grinding.
6-axis CNC mills are a step above 5-axis milling machines. These remarkable machines use an additional rotation axis along the Z-axis, resulting in a noticeable speed improvement over the 5-axis variety. The extra axis allows the tool to have more movement and transitions at higher speeds without sacrificing accuracy.
A 6-axis machine is ideal for volume machining steel, aluminum, and cast iron. It is powerful enough to convert the raw metal into the final product without additional equipment.
It&#;s a multi-functional piece of manufacturing equipment that can permit end-users to carry out various operations from one machine. Automotive machining centers can use this machinery for drilling, milling, and turning. Each of these procedures requires a modification to the tool or software control system, but the process will improve productivity and reduce production time.
This milling machine can reduce cutting times by up to 75% compared to other types of CNC machines, but it does have limitations. Most components made with 6-axis milling machines are complex configurations like engine blocks or turbines. If you are machining a product that only has straight, vertical cuts, the rotations on the X, Y, and Z axes are unnecessary, so there is no advantage to using a 6-axis CNC machine for that specific workpiece.
CNC machine tools can make quick, complicated cuts into a workpiece that other machinery cannot do. By using a computer-driven cutting tool to transform raw metals, plastics, and wood into a final product, you will have consistent product quality, better accuracy, increased production speed, and operator safety. Depending on the requirements for your parts, different types of CNC machines will be more appropriate than others.
The Federal Group USA has been providing precision CNC machining to clients since . We use state-of-the-art 3-axis milling machines, 4-axis machines, and 5-axis CNC machines to create high-quality products that match our client&#;s desired specs. The Federal Group USA serves a wide range of industries, including furniture manufacturers, healthcare and consumer goods, and the automotive industry.
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Multi-axis CNC machines are the manufacturing standard for most major manufacturers. Understanding &#;what is multiaxis machining?&#; opens a new world of possibilities for your manufacturing or fabrication facility.
Multi-axis machining can significantly increase production numbers and the production quality of any manufacturing setup. In addition, this machining process can create parts that you cannot manufacture with conventional technology.
This article will have an in-depth discussion on multi-axis machining, its working process, various types, advantages, limitations, and a lot of other information.
What is Multi-axis Machining?
Multi-axis machining is the machining process where the machine tool can move in four or more directions. Each direction is referred to as the degree of freedom. Multi-axis CNC machining can involve different numbers of axes, such as 4, 5, 6, 8, 10, and 12.
However, the complexity of the machine increases significantly as the number of axes increases. An important thing to note is that 3-axis CNC machining is not a part of the multi-axis machining process. This is because the cutting tools move only in X, Y, and Z axes in 3-axis machining.
Modern multi-axis machining mnachines are controlled by Computer Numerical Control (CNC). CNC technology can automate the movement of the cutting tool and other machine parts. CNC control works on software programs created for the particular part beforehand.
Richard Kegg invented the foundation of multi-axis CNC machining in . Multi-axis machining was also practiced before that time. However, early multi-axis machining did not involve CNC technology. Machining was done with the movement of CAM plates manually.
Manual multi-axis machining was inconsistent and slower. Additionally, there was the added factor of human error. The application of CNC technology to the process has completely changed how it works.
How Multi-axis Machining Works?
Multi-axis machining is a step-by-step process. The particular working can vary based on the type of multi-axis CNC machine used. However, certain steps are common to all multi-axis machines. These steps are:
Firstly, it is important to create the graphical design of the part. The various dimensions and features of the part are mentioned in this design.
A CAD model of the part is created on Computer Aided Design software. The CAD model contains all the details of the part in digital graphic format.
The CAD model is converted to the Computer Aided Manufacturing (CAM) format. This is because CNC machines recognize CAM language. This step is done in CAM software.
The operator does the machine setup. This includes loading the part, transferring CAM software to the machine, and selecting various required settings.
Once setup is complete, the operator executes the program. The machine starts working on the part.
The operator checks the part to see if any reiteration is required. If everything is fine, the operator unloads the part from the machine.
Multi-axis machining differs from conventional machining in the cutting tool movement. Multi-axis machining center can move the cutting tool in four or more directions. However, a conventional machining center can only cut tool movement in three directions at most.
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What are the Main Components of a Multi-axis CNC Machine?
The main parts of a multi-axis CNC machine are:
Different Configurations in Multi-axis CNC Machining
There are many different configurations of a multi-axis machining center. These machines mainly differ in the number of axes and how they work together. Axis refers to the direction in which a cutting tool can move. There are two types of axis in CNC machining:
Now let us go through the many different types of multi-axis machining and how they utilize the axes mentioned above:
3+2 axis machining is also known as positional 5 axis machining. It is very different from generic 5-axis machining. The machine can undergo three linear axes motion like any other CNC machine. Additionally, it can move the workpiece in two rotary axes and lock it in place. After that, conventional 3-axis machining can execute on the workpiece.
The main advantage of 3+2 axis machining is that it increases the workable faces of the workpiece. This comes at a comparable cost of a 3-axis CNC machine, making the process cost-effective. However, it misses out on the real-time performance of a 5-axis machining center.
4+1 axis CNC machines can move simultaneously in four directions. 3 are the linear axes X, Y, and Z, and the fourth is any one of the rotary axes. The fifth direction is positional. This means that the workpiece can move in the fifth axis, lock position, and then 4-axis machining can carry out on the workpiece.
5-axis machining is also known as simultaneous 5-axis machining to separate it from 3+2 and 4+1 machining. The machine tool is capable of motion in 5 different axes simultaneously. Three of these are the linear axes- X-axis, Y-axis, and Z-axis. Other two are the rotary axes: A-axis and B-axis. Simultaneous movement of the cutting tool in five axes provides higher machining speed than 3+2 and 4+1 configurations.
6-axis machining combines all three linear axes and all three rotary axes. There is movement in the three axes: X-axis, Y-axis, and Z-axis. The cutting tool can also move in the A, B, and C axes. Including all six axes provides high transition speed for the machining operation. 6-axis machining is commonly used in the automobile industry.
7-axis CNC machines have three linear axes (X, Y, and Z), three rotary axes (A, B, and C), and a seventh E-axis. The E-axis is the rotary axis in the direction of twisting of the arm holding the cutting tool. There are generally two spindles present in a 7-axis CNC machine.
A 9-axis CNC machine combines the operations of a 4-axis machine and a 5-axis machine. Common example of 9-axis machines are hybrid mills used for surface machining of the part. The 4-axis machine is usually a lathe for internal milling. This enables internal and external machining of the parts in a single setup.
12-axis machining configuration typically comes with two 6-axis cutting tools. Each cutting tool is capable of independent movement. The purpose of 12 axis machining center is to increase the productivity and cutting speed of the machine. The 12-axis machine also has unparalleled accuracy.
The rotary table is a common feature found in multi-axis CNC machining. It allows the work table to rotate around a central axis. The rotation of workpiece provides the operation of a higher axis machine on a lower axis equipment. This increases the machine capabilities while reducing costs.
Tilting rotary table machining configuration allows the rotation of the work table in the horizontal plane. In addition, the work table can also tilt up to a certain axis. This allows for very complex machining operations in a lower axis CNC machine.
Multi-angle heads are attachments used in multi-axis machining. The cutting head has the capability of tilting at multiple angles. This allows for complex surface finish and contouring operations in multiaxis machining.
Hexapod machines are a variation of multiaxis machines. It contains six actuators in a hexagon shape. The actuators are capable of simultaneously working on the workpiece. The scale of the hexapod machines can be toned down to the required size. This is why hexapod multiaxis machines are commonly used in micromachining and optical manufacturing applications.
What are the Advantages of Multiaxis Machines?
There are many advantages of using multiaxis machines. These are:
What are the Limitations of Multiaxis Machining?
In most cases, multiaxis machines are a better option than any other alternative. However, there can be some limitations to the process. These are:
What are Common Multiaxis Machining Operations?
There are many different types of multiaxis machining operations commonly used in the manufacturing sector. Some of these operations are:
What are the Applications of Multi-axis Machines in Different Industries?
Multi-axis CNC machining finds usage in a lot of different industries. Some of these industries are:
Aerospace industry requires parts with ultra-high precision. Therefore, multi-axis CNC machining is the preferred manufacturing method for this sector.
The automotive industry requires high production numbers and precision. Multiaxis machining meets the challenges of this industry quite well even on complex engine parts. Additionally, it can work on the high-hardness metals and alloys used in this industry.
Jewelry making requires complex machining centers that can work on a minute level. Modified multiaxis machining and hexapod machining centers are used for this purpose.
Furniture industry heavily relies on multi-axis lathes and swiss type lathes for making furniture. Parts such as table legs, wooden carvings, and glass and marble tops are made using multi-axis machining methods.
Medical industry creates implants and devices that are crucial for life sustaining functions. Therefore, it requires ultra high precision and elimination of any possible defects. Multi-axis CNC machining is the preferred way to manufacture parts for this industry.
Defense industry requires parts with high complexity made out of the toughest materials. The production is in low numbers but the customization is usually of a high degree. Therefore, multi-axis CNC machining is applied for making these parts.
The marine industry uses large-scale construction of parts for boats, ships, yachts, and other sea transportation. Multi-axis machining creates these parts which are then assembled together at a later stage.
Safety Considerations for Multi-axis Machining
Multi-axis CNC machining uses cutting tools that can easily pierce through metal and alloys. Therefore, there are many safety considerations to ensure no harm takes place to the workforce or the workplace.
How to Choose a Multiaxis Machine?
Choosing a multiaxis machine can be a tough choice between various manufacturers. Here are some of the factors you can consider when making such a choice:
Future Trends in Multi-axis Machining
Multi-axis machining is moving towards micromachining to assist in semiconductor-based manufacturing. Parts in the electronics and IT industry are shrinking down to the lowest possible sizes. Multi-axis machining is being used in fabrication lines for smartphones and computer chips. PCBs for other electronics are also manufactured with such micromachining technology.
Robotics and automation are also crucial parameters for future growth of multiaxis machining. More and more manufacturers are automating the entire assembly line for faster and more consistent product. Therefore, multiaxis machining options like the hexapod manufacturing process are developing rapidly.
Endnotes
Multiaxis machining is becoming the preferred manufacturing process for most medium to large scale industries. With a marginally higher investment than three axis machine parts, multiaxis machines come with a lot of benefits. Additionally, the ability to machine complex shapes is second to none. If your industry requires consistency, high production speed, precision, or complex parts, multi-axis machining can be a great fit for you.
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