The need for precision in machining complex parts and a more efficient operation increased part manufacturers’ reliance on 5-axis CNC machining. Hence, precision CNC machining services are adapting to the trend and trying to take advantage of the higher inflows of orders associated with the choice.
Many machining services adopting the technique mean that many mediocre services are available to fulfill orders. Hence, part manufacturers must understand what they need to know before choosing any 5-axis CNC machining service to ensure a quality-focused manufacturing process.
When choosing 5-axis CNC machining services, you need to consider the process, materials compatibility, and other things we discussed in this article.
How Does 5 Axis CNC Machining Work?
Several CNC machining techniques exist, each with unique advantages. Although many services widely adopt 5 axis CNC machining performance-wise, the previous methods (3-axis, 4-axis, 3+2-axis, etc.) are still functioning and applicable in several scenarios.
This means that before you outsource to a 5-axis precision CNC machining service, you need to know whether what you want can be easily machined by previous techniques. You can ascertain this by understanding how 5-axis CNC machining works and comparing it to other methods like 3-axis and 4-axis machining
5-axis CNC machining is a technique of unmatched precision suitable for manufacturing parts with complex designs. In terms of compatibility with complex parts, it can be compared to 3D printing.
A 5-axis CNC machine differs from traditional CNC machines by its ability to move in five directions instead of three (3-axis) and four (4-axis). The operation of a 5-axis CNC machine involves the following coordinate system:
- X-Axis: Moves left to right.
- Y-Axis: Moves front to back.
- Z-Axis: Moves top to bottom.
- A-Axis: Rotates around the X-axis (tilts backward and forward).
- B-Axis: Rotates around the Y-axis (tilts and spins from left to right).
These additional movements are possible due to the addition of rotation or tilt to the tool spindle or work holding platform. As a result, the efficiency of the machining process increases, especially when machining complex geometries.
How do 5-Axis CNC Machines Service operate?
You must understand how they work to choose the right CNC machine service provider effectively. This will allow you to assess the service and understand what to expect. We will give a summary of the general workflow below:
- Initial Consultation
This includes customer inquiry and requirement analysis. Here, you will contact the CNC machining service provider about your project, and the service provider will discuss the details (material specifications, part design, quantity, and deadlines) with you.
- Design and Engineering
The customer can provide the CAD (Computer-Aided Design) files, or the service provider can help. The service provider also assesses the files. If you have an idea for designing, creating your own CAD file can be beneficial, but if you don’t, you should choose a service provider to help you design and refine the CAD files.
This stage includes a design review and detailing of the part’s technical specifications, like tolerance, surface finishes, and post-manufacturing processes.
- Quotation and Agreement
After settling the design stage, you get a quote, which is a cost based on the material, machine time, labor, and other additional services required. Some service providers have an automatic quotation system, while some accept installment payments. Upon agreement, you will approve the quotation and place an order.
- Material Procurement
The service provider handles this, but you should look for information on their material sourcing procedure to ensure that the materials used meet quality standards and specifications.
- Machining
After programming, simulation, and set-up, the machining process starts. You have little control over this, although, at the beginning of the process, you must know the types of 5-axis CNC machines the precision centers have in their factory to ensure efficient and error-free machining.
- Post-Processing
For parts that need post-processing, ensure the precision CNC machining services have the necessary facilities.
- Quality Inspection
The process must be standardized to ensure the parts meet the required specifications and tolerances. Ensure the service providers’ protocols include generating a quality report documenting the inspection results and confirming that parts meet customer requirements.
- Packaging and Delivery
The service provider’s delivery process must ensure that machined parts are not damaged during transportation. Also, note a track record of keeping to the delivery time.
Throughout these stages, the best 5-axis CNC machining services should have a good customer support and feedback system to ensure the quality and performance of the machined parts and address any issues or further requirements the customer may have.
What Material is Suitable for 5-Axis CNC Service?
5-axis CNC machines can work with various materials, making them versatile for multiple industries. The choice of material depends on the specific requirements of the project. Common materials include:
Metals
Metals are the most common materials for CNC machining due to their mechanical, thermal, and electrical properties. Machining metals, however, depend mainly on the hardness of the bits and materials and the sophistication of the machine.
For example, it is easier to machine aluminum than titanium because the former is softer. Likewise, bits made from solid materials like carbide, ceramic, and CBN (Cubic Bore Nitride) can handle harder materials than high-speed steel bits. Lastly, sophisticated machines are better for hard metals than standard machines.
Plastics
Plastics are also very machinable, although each has unique properties that can affect its machinability. For example, ABS is a prototyping material with good mechanical properties and machinability. However, it can catch fire under machining stress.
Composites
Composites, like carbon fiber reinforced polymers (CFRP), have a high strength-to-weight ratio. Hence, they are a common material in the aerospace and automotive industries.
How Much Does 5 Axis CNC Service Cost?
Another thing you need to consider before outsourcing to a 5-axis CNC machining service is the cost. Every service has a unique cost depending on several factors, including the part’s complexity, material choice, machine time, and labor. Here are some key considerations:
Machine and Setup Costs
5-axis CNC machines are more expensive than their 3-axis counterparts due to their advanced capabilities and higher precision. The initial setup cost can also be higher as it involves more complex programming and fixture design.
Material Costs
The type of material used significantly impacts the overall cost. Metals like titanium and Inconel are more expensive than aluminum or steel. Similarly, exotic materials and composites can add to the price.
Labor and Programming
Operating a 5-axis CNC machine requires skilled technicians proficient in complex programming. The labor cost can be higher due to the need for experienced operators and the additional time required for programming and setup.
Production Volume
Higher production volumes can reduce the per-unit cost as the setup cost is spread over more parts. Bulk orders often benefit from economies of scale, making them more cost-effective.
Post Processing
Additional finishing processes, such as polishing, coating, or painting, can add to the cost. These processes may be necessary to achieve the desired surface finish and aesthetic qualities.
How Long Will I Get 5 Axis CNC Parts?
The delivery time for 5-axis CNC parts depends on several factors, including the part’s complexity, production volume, and the workload of the machining service provider. Complex designs mean a longer planning and machining time.
Delays in sourcing specific materials can impact the timeline. Lastly, the capacity and workload of the service provider will determine the machining time. Established providers with advanced equipment and efficient processes can often deliver faster.
Here’s a general overview:
Prototyping
The turnaround time for prototyping is usually shorter, ranging from a few days to a few weeks. This quick turnaround allows for rapid iteration and testing of new designs.
Small to Medium Production Runs
For small to medium production runs, the delivery time can vary from a few weeks to a couple of months, depending on the complexity of the parts and the number of units required.
Large Production Runs
Large production runs may take several months, especially if the complex parts require multiple setups or extensive postprocessing.
Conclusion
There is an increased reliance on 5-axis CNC machining services due to the need for complex parts or a more efficient machining operation. However, this has led to mediocre machining services available to fulfill orders.
Part manufacturers must understand a few things about choosing and outsourcing to a 5-axis CNC machining service. Hence, we discussed the process and other considerations when choosing one.
