What is 5-axis milling?

5-axis milling is an advanced machining technique used in the metalworking industry. It refers to the process of using a milling machine with five axes of motion to perform complex and precise operations on workpieces of various shapes and materials. Compared to traditional milling, 5-axis milling offers numerous advantages, making it a popular choice for many manufacturers and suppliers.

The advantages of 5-axis milling over traditional milling

Traditional milling can still be a tremendous solution for many production jobs. However, when the issue and designs become more complex, 5-axis milling can offer a solution. There are a number of advantages that distinguish 5-axis milling from traditional milling.

1. More complex geometries: 5-axis milling makes it possible to machine complex shapes, contours and angled surfaces that are difficult or impossible with traditional 3-axis milling. It offers more design freedom and enables the realization of complicated components.
2. Less repositioning: With 5-axis milling, multiple operations can be performed in one motion. Repositioning of the workpiece is therefore reduced. This saves time and increases the accuracy of the finished product.
3. Higher accuracy: The two additional axes of movement of a 5-axis milling machine provide greater flexibility and precision in achieving difficult angles and contours. This makes accuracy even better, especially with complex designs.
4. Shorter lead times:Lead times are reduced and production delivery can therefore be faster. Thanks to the 5 axes, complex operations are performed faster.
5. Cost savings: Enabling 5-axis milling does require investment. In addition to advanced machinery, programming expertise is needed. Ultimately, this also pays off. Fewer movements, shorter lead times, less residual material and faster delivery provides cost savings.

How do 3- and 5-axis milling work?

3-axis milling

In 3-axis milling, the milling machine can move along three axes: the X axis (horizontal), the Y axis (vertical) and the Z axis (depth). This allows the machine to perform operations on flat surfaces and simple three-dimensional shapes. Thus, the tool can move horizontally, vertically and in depth. Complex contouring on inclined surfaces is also possible, although this requires repositioning of the workpiece.

5-axis milling

In 5-axis milling, the milling machine can move on two additional axes in addition to the X, Y and Z axes. The A and B axes are used for tilting around the X and Y axes. These additional movements make it possible to machine complex geometric shapes including inclined surfaces. The workpiece then does not have to be repositioned.

In short, 3-axis milling offers basic machining on flat surfaces, while 5-axis and 6-axis milling offer more advanced capabilities for machining complex shapes and contours without repositioning the workpiece. 5-axis and 6-axis milling are suitable for producing complex and precise parts, with 6-axis milling being the most advanced and versatile option.

The process of 5-axis milling step by step

A machine capable of 5-axis milling works by using multiple axes of motion to position the tool in different directions. To get from design to result, several steps are performed.

1. Step 1: Fasten the workpiece.
   The workpiece is fastened securely using clamps and clamping devices. This can be wood, metal or another type of material. It is important that the workpiece does not move during milling.
2. Step 2: Tool selection
   Based on the design and material, the appropriate tool is selected and attached to the 5-axis milling machine.
3. Step 3: Program
   A CNC (Computer Numerical Control) program is set up on the milling machine. The program contains the instructions for the movements and operations to be performed. In it, coordinates, speeds, depth of cut and other parameters are specified.
4. Step 4: Positioning the axes
   The axes are brought into the correct position based on the coordinates of the CNC program. All 5 axes have very precise positions set by the machine.
5. Step 5: Perform milling operation
   When everything is in position, the milling operation can be performed. The machine is computer-controlled and follows the movements according to the programmed path. The tool approaches the workpiece from different angles. This is all made possible by the moving axes.
6. Step 6: Checking the machine
   During milling, the machine continuously checks that all movements and operations are happening according to plan. If this does not seem to be the case, the computer corrects it immediately. There is no room for error. Quality and accuracy are guaranteed.
7. Step 7: Finish editing

Once the operation is accomplished, the tool retracts and the workpiece can be removed. The workpiece is inspected but if all goes well, this one has succeeded perfectly.

Batchforce facilitates in 5-axis milling and more

Need 5-axis milling, but can’t find the right partners or manufacturers to help you do it? Choose Batchforce. A good, reliable partner is essential. We become part of your company and ensure that all your CNC productions, including 5-axis milling, are taken care of. Furthermore, you secure the following benefits for you and your company.

• Everything organized in one convenient dashboard
• Delivery of your applications within 4 weeks
• The best manufacturers and suppliers worldwide to take care of your application
• Sourcing from 1 to 1000+ parts possible
• Dedicated specialists to help you from A to Z

What types of cutters are there?

There are different types of cutters that are used, some of them are:

• Finger milling cutters have multiple cutting edges and are used for milling grooves and slots.
• Alternate plate milling uses interchangeable cutting plates that attach to the milling head. A versatile method of milling.
• Ball milling cutters have a spherical cutting edge. This is ideal for curved surfaces and cavities. In addition, these can be used to make round cutouts.
• Surface milling is used for machining flat surfaces.
• Corner milling mills corners, machining edges and making angled components.

These are just a few examples. The world of metalworking has many more types of milling. The possibilities are endless and almost anything can be made thanks to advanced milling machines from our manufacturers and suppliers.