Five-axis machine tools and machining guide : working principles, machine types and prices, and related costs
- Five-axis machine tools and machining guide : working principles, machine types and prices, and related costs
- What are five-axis machine tools and machining?
- What are the five different axes of a 5-axis CNC machine tool?
- How much does it cost to machine a part using a 5-axis CNC machine?
- 5-axis CNC machine tool price
- Basic principles and working process of CNC five-axis machine tools
- Types of five-axis CNC machine tools
- Industries, applications and materials of five-axis CNC machining
- Five-axis CNC machining technology compared to 3D printing technology
- Why choose Elimold as our outsourced supplier of 5-axis CNC machined parts?
- in conclusion
The advent of five-axis CNC machining marks a major revolution in machine tool technology, propelling various industries into a new era of manufacturing precision and efficiency, surpassing traditional three-axis machine tools. Unlike traditional three-axis milling machines that move the tool in three dimensions, five-axis machining centers integrate two additional rotary axes, allowing the tool to approach the workpiece from virtually any direction. This capability simplifies setup and reduces the need for multiple fixtures. It also enhances the ability to machine complex designs that were previously impossible.
This article will delve into the principles, types, and applications of five-axis CNC machine tools. We will gradually reveal the profound impact and wide-ranging applications of five-axis technology in modern manufacturing, helping us to gain a deeper understanding of this technological marvel.
What are five-axis machine tools and machining?
Five-axis machining is an advanced CNC technology that enables the cutting tool to move simultaneously along five different axes, thus enhancing the capabilities of standard machining workshops. This complex system not only moves along the traditional three linear axes (X, Y, and Z) like a three-axis CNC machine tool, but also includes rotational motion about the A and B axes. The term “five-axis” in five-axis CNC machine tools refers to this comprehensive range of motion. In five-axis simultaneous machining, the cutting tool can pivot while cutting, enabling efficient and precise machining of complex geometries and surfaces. This capability makes five-axis solutions an indispensable part of industries requiring complex designs and extremely high precision. Understanding these axes and their functions is fundamental for anyone needing to understand the advanced dynamics of CNC machine tools in modern machining environments.
What are the five different axes of a 5-axis CNC machine tool?
In a 5-axis CNC machine tool, “5 axes” refers to the five axes along which the tool can move and rotate simultaneously. A typical 5-axis CNC machine tool has three linear axes (basic axes) and three rotary axes (A, B, and C). The 5-axis machine tool will move along the linear axes and two rotary axes. The following is a basic explanation of the different axes of a CNC machine tool.
linear axis
Standard 3-axis machining is performed along the X, Y, and Z axes. These three linear axes represent the directions in which the spindle or workpiece can move.
| X-axis | The X-axis represents the horizontal movement of the cutting tool along the length of the machine bed. It can move from left to right or from right to left, depending on the machine configuration. Movement along the X-axis enables CNC machining operations such as milling, drilling, and contouring. |
| Y-axis | The Y-axis represents the lateral movement of the cutting tool, which can be from front to back or from back to front, depending on the machine configuration. Movement along the Y-axis enables CNC machining operations such as side milling, grooving, and contouring. |
| Z-axis | The Z-axis represents the vertical movement of the cutting tool. Depending on the type of 5-axis CNC machine tool, it can move up and down. Movement along the Z-axis enables CNC machining operations such as drilling, tapping, and boring. |
Rotation axis
Using rotary axes means that the machine can rotate the part or cutting tool (spindle head) around one of the previously established linear axes. In 5-axis CNC machining, different machines will use different combinations of the following rotary axes (A & B, B & C, or A & C).
| A-axis | The A-axis represents the rotational motion of the cutting tool about the X-axis, including tilting or rotating. This axis offers greater flexibility and compatibility with undercutting, chamfering, and angled features. |
| B-axis | The B-axis represents the rotational motion of the cutting tool around the Y-axis. This axis enables machining of multi-faceted surfaces and features such as deep cavities, complex contours, and curved surfaces. |
| C-axis | The C-axis represents the rotational motion of the cutting tool about the Z-axis – it is either vertically tilted or rotated. |
How much does it cost to machine a part using a 5-axis CNC machine?
The price of 5-axis CNC machining services varies depending on the factory providing manufacturing services or the project, as well as the materials, processes, dimensions, and region. The more complex the part design, the longer the machining time, and the higher the price. Similarly, different materials, processes, and dimensions also affect the price, and prices differ between regions; for example, manufacturing costs in the United States are typically much higher than in China.
At Elimold in China, the base price for a standard 5-axis CNC machining service is $300 USD per part. For projects requiring a large number of parts with complex designs, the price can reach hundreds of thousands of USD. This depends on the complexity and technical difficulty of the project, as well as the client’s specific needs. If high precision tolerances, high-quality surface finishes, rapid production, and excellent after-sales service are required, the price may be even higher.
In the United States, the standard hourly rate for five-axis CNC machining is approximately $120 to $250 or more. Machining costs for high-precision parts can exceed this range. Some machining workshops may offer slightly lower base rates (around $100 to $200 per hour) depending on the machine type and location. Additionally, some machining service providers charge a minimum processing fee or basic fee to cover preparation, fixtures, inspection, and quality assurance costs. These fixed costs can make the production cost of a single prototype prohibitively high compared to bulk orders.
5-axis CNC machine tool price
The purchase cost of five-axis CNC machine tools varies greatly. It can range from one thousand US dollars to five hundred thousand US dollars. The price depends on the size, functions, and type of CNC machine tool.
- The price of a 3+2 5-axis CNC milling machine ranges from $35,000 to $200,000.
- The cost of a trunnion-type 5-axis CNC milling machine is approximately US$200,000 – 500,000.
- A rotary 5-axis CNC milling machine costs approximately $150,000 – $500,000.
- Mini 5-axis CNC milling machines range in price from $3,000 to $10,000.
- The price of a 3+2 5-axis small CNC milling machine ranges from $25,000 to $40,000.
Basic principles and working process of CNC five-axis machine tools
Five-axis CNC machine tools represent a revolutionary advancement in machining technology. They offer a multi-dimensional approach to manufacturing parts with complex designs and high precision. The following outlines the entire working principle of a five-axis CNC machine tool from design to execution, detailing each step in the process:
| Design phase | It all begins with design. Engineers use computer-aided design (CAD) software to create a detailed 3D model of the part to be manufactured. This model contains all the necessary specifications to guide the manufacturing process. |
| CAD to CAM conversion | Once the CAD model is completed, it is exported to Computer-Aided Manufacturing (CAM) software. In the CAM software, the model is used to plan and simulate machining operations. CAM software is crucial for determining cutting toolpaths and optimizing the machining process to improve efficiency and accuracy. |
| Toolpath generation | CAM software generates specific toolpaths. The program is designed based on the performance of the five-axis CNC machine tool. These paths determine the movement trajectory of the cutting tool, ensuring that all features of the part can be accurately machined. |
| G-code generation | The toolpath is then converted into G-code that the CNC machine tool can recognize. This code provides precise instructions on how each axis of the machine tool should move during the machining process. |
| Machine tool setup | The five-axis CNC machine tool is equipped with the necessary cutting tools and fixtures before machining. This setup includes fixing the workpiece on a rotary table to enable additional motion axes. |
| G code execution | The G-code is loaded into the control system of the CNC machine tool. The machine tool starts running according to these instructions, requiring minimal human intervention. |
| Synchronous motion | At the start of machining, the five axes in a five-axis CNC machining system allow the tool to move along the X, Y, and Z axes, while simultaneously rotating around the A and B axes. This capability enables the tool to maintain optimal angles at all times, allowing for the machining of complex areas without stopping and readjusting the part orientation. |
| Use shorter cutting tools | The flexible motion allows for the use of shorter cutting tools that are less prone to vibration and enable higher rotational speeds, thereby improving surface finish and machining accuracy. |
| Continuous processing | The machine tool executes the program, moving smoothly step by step according to the G-code, and adjusting the rotary and linear axes. This process reduces the need for multiple clamping operations, minimizes manual labor, and significantly shortens production time. |
| Final verification and finishing | After machining, the parts undergo precision and quality inspection. Any necessary finishing work is then performed as needed to meet precise specifications. |
Types of five-axis CNC machine tools
This section introduces the various types of machine tools available and their unique machining capabilities. In addition to the standard three linear axes, five-axis CNC machine tools have revolutionized the machining of complex parts. This configuration allows the tool to move around all five faces of the part in a single setup, thus improving accuracy and reducing time. It increases the possibility of machining fine details and high-speed operation. Below are the main types of five-axis CNC machine tools, each designed to meet specific needs and applications within an enterprise:
| Rotary worktable + rotary spindle head | This configuration includes a rotary table supporting the workpiece and a rotary spindle head. This configuration enables the machining of complex geometries and is particularly suitable for parts that can be machined from multiple angles without the need for repositioning. |
| Double rotary table | This design features a second rotary axis on the main worktable, enabling operators to handle more complex parts and perform five-axis machining with greater control and flexibility. |
| Dual-pivot spindle head | This design integrates two pivot points within the spindle head itself, enabling advanced articulation of the cutting tool. It is particularly useful for complex aerospace components requiring multiple tool angles. |
| Rotary table + table journal | This compact design secures the part to the journal, providing stability and facilitating the machining of complex parts. Because the spindle head has no pivot, it can focus on movement around the part, thus optimizing the machining process. |
| Types of rotating mechanisms | These include drop-type rotary heads, drop-type worktables, double rotary heads, double rotary worktables, and single-pendulum single-rotation mechanisms. Each type has unique advantages and can handle different machining tasks, ranging from heavy-duty cutting to fine machining. |
Industries, applications and materials of five-axis CNC machining
5-axis CNC machining is a manufacturing process suitable for applications in various industries requiring high precision, complex shapes, and tight tolerances, as well as a wide range of materials. The following is a summary of the different industries, applications, and corresponding materials that 5-axis machine tools can serve.
| Industry | Typical Applications/Components | Why 5-Axis Is Required | Common Materials |
| Aerospace & Aviation | Turbine blades, impellers, blisks, engine housings, structural brackets, airframe fittings | Complex free-form surfaces, compound angles, deep cavities, high accuracy in a single setup | Aluminum alloys (7075, 7050), Titanium alloys (Ti-6Al-4V), Inconel, Hastelloy, Stainless steel |
| Automotive (Performance & EV) | Cylinder heads, intake manifolds, turbocharger housings, motor housings, lightweight structural parts | Multi-angle features, complex internal channels, reduced fixturing for accuracy | Aluminum alloys, Magnesium alloys, Alloy steel, Stainless steel |
| Medical & Healthcare | Orthopedic implants, bone plates, spinal components, dental abutments, surgical tools | Organic geometries, high surface quality, tight tolerances, multi-side machining | Titanium alloys, Cobalt-chromium, Stainless steel (316L), PEEK, Medical plastics |
| Defense & Military | Weapon system components, missile guidance housings, radar parts, armored connectors | Complex geometry, high structural integrity, precision and repeatability | Titanium alloys, High-strength steel, Aluminum alloys, Nickel-based superalloys |
| Energy (Oil, Gas & Power) | Pump impellers, valve bodies, turbine components, flow control parts | Multi-axis internal flow paths, complex profiles, heavy-duty materials | Stainless steel, Duplex steel, Inconel, Monel, Carbon steel |
| Electronics & Semiconductor | Precision housings, heat sinks, test fixtures, optical frames | Fine details, multi-face accuracy, thin-wall machining | Aluminum alloys, Copper alloys, Brass, Engineering plastics |
| Robotics & Automation | Robotic arms, joints, gear housings, end-effectors | Multi-surface machining with tight alignment requirements | Aluminum alloys, Alloy steel, Stainless steel |
| Industrial Machinery | Precision molds, dies, complex mechanical assemblies, custom fixtures | Deep cavities, compound angles, reduced setup errors | Tool steel (H13, D2), Aluminum, Stainless steel |
| Mold & Tool Making | Injection mold cores, cavities, die-casting molds, blow molds | Free-form surfaces, high surface finish, accurate parting lines | Tool steel, Pre-hardened steel, Aluminum alloys |
| Marine & Offshore | Propellers, impellers, pump housings, corrosion-resistant fittings | Complex hydrodynamic surfaces, corrosion resistance | Bronze, Stainless steel, Duplex steel, Aluminum bronze |
| Optics & Precision Instruments | Optical mounts, lens holders, alignment components | High precision and angular accuracy | Aluminum alloys, Stainless steel, Brass |
| Aerospace Prototyping & R&D | Functional prototypes, flight-test parts, experimental components | Design validation with complex geometries and rapid iteration | Aluminum, Titanium, Engineering plastics |
Five-axis CNC machining technology compared to 3D printing technology
Unlike 5-axis CNC machining, 3D printing is an additive manufacturing process that builds a component one layer at a time. While these technologies operate differently, their applications overlap considerably. They all offer high precision, rapid turnaround time, improved repeatability, and excellent surface finishes.
At the time, 3D printing did not require special fixtures or tools, resulting in low initial setup costs. However, 5-axis CNC machine tools offer significantly better dimensional accuracy than 3D printing. They can precisely machine both small and large parts. Achieving extremely tight tolerances through 3D printing would require additional post-processing.
Why choose Elimold as our outsourced supplier of 5-axis CNC machined parts?
Choosing the right location to outsource a five-axis CNC machining project is crucial. Outsourcing to companies in developed countries, such as the United States, can be costly; however, partnering with companies in regions with lower operating costs, such as China, can yield competitive pricing without compromising the final quality of the parts.
Elimold, a Chinese company, can provide high-quality CNC 5-axis machined parts at relatively favorable prices. This makes outsourcing a viable option for reducing basic machining costs, especially for companies looking to optimize their budget without sacrificing high quality. So what are you waiting for? Start your custom parts sourcing task and get a CNC quote!
in conclusion
Five-axis CNC machining has had a profound and far-reaching transformative impact on modern manufacturing. Advanced CNC systems enable horizontal machining and tool configuration, opening up new possibilities for parts production. As we have discussed, five-axis technology improves accuracy and cost-effectiveness by reducing the number of setups. It can efficiently machine complex geometries that are difficult for traditional three-axis machine tools to handle, highlighting a leap forward in manufacturing technology.
Looking ahead, the development momentum of five-axis CNC machining is expected to accelerate. Future innovations are anticipated to integrate with technologies such as artificial intelligence, robotics, and big data, making these machine tools more intelligent, versatile, and precise. For manufacturers, closely monitoring these developments is not just advice, but crucial. Rapid adaptation will be essential as machining technologies continue to advance. For companies interested in cutting-edge manufacturing technologies, obtaining quotes for custom parts is a key step towards future production.