Multi-axis machining is an advanced manufacturing technology capable of processing complex geometries in a single setup. Traditional CNC machining typically uses three axes—X, Y, and Z—requiring multiple adjustments and repositioning of the workpiece. In contrast, multi-axis machining adds additional rotational axes (such as the A and B axes), allowing the tool or workpiece to move in multiple directions. This not only increases machining flexibility but also significantly reduces the time spent on repositioning.
The core advantage of multi-axis machining lies in its ability to produce complex-shaped parts in a single setup, greatly improving production efficiency and machining precision. As a result, industries with high precision requirements, such as aerospace, medical device manufacturing, and complex automotive components, have gradually adopted multi-axis machining technology.
Types of Multi-Axis CNC Machining
3-Axis CNC Machining
This is the most basic machining technology, with movement restricted to the X, Y, and Z axes. It is suitable for simpler parts and standard shapes.
4-Axis CNC Machining
Building on the 3-axis system, 4-axis machining adds a rotational axis (usually a rotation around the X-axis), allowing for more efficient side machining and reducing the need for repositioning. This makes 4-axis machining suitable for more complex part designs.
5-Axis CNC Machining
5-axis machining is one of the most widely used technologies for complex part manufacturing, particularly in the aerospace and medical fields. By adding two rotational axes, 5-axis machining allows precision machining of multiple surfaces in a single setup, significantly enhancing the ability to handle complex geometries.
3+2 Axis CNC Machining
This configuration is similar to 5-axis machining, but the tool only moves along three axes, with two additional rotational axes used to adjust the angle of the workpiece. It is ideal for parts requiring specific angled features.
6-Axis CNC Machining
6-axis machines include an additional rotational axis designed to enhance part manufacturing capabilities, improve efficiency, and minimize setup times to reduce lead time.
7-Axis CNC Machining
7-axis machines offer more movement and mechanical arms, designed for extraordinary work motion. In addition, they allow very precise tasks to be performed with high accuracy.
9-Axis CNC Machining
9-axis CNC machining combines turning and milling operations. It enables the formation of complex parts with different configuration shapes in a single setup, improving the efficiency of the production process. It is particularly suitable for constructing precision-engineered components.
12-Axis CNC Machining
Finally, 12-axis machining involves special rotational movements around both length and width, with traveling axes moving along both dimensions. It can be used in cutting-edge composite materials that require high-precision applications.
Advantages of Multi-Axis Machining
1. Single Setup Efficiency
In traditional machining, multiple repositioning of the workpiece is often required to complete all processes. Multi-axis machining allows multiple surfaces to be processed in a single setup, not only reducing repositioning time but also lowering the chance of errors.
2. Improved Precision and Accuracy
Multi-axis machining offers better tolerance control, especially in high-precision industries such as aerospace and medical device manufacturing. This precision makes part production more reliable and reduces the scrap rate.
3. Complex Geometry Processing
Multi-axis machines can process structures and shapes that traditional machines cannot. This ability makes them suitable for processing parts with complex structures.
4. Enhanced Surface Finish
These machines offer more manufacturing steps with precision that requires sharper taper cuts and transitions. This achieves a better surface finish, reduces the number of finishing operations required, accelerates contract completion, and lowers costs.
5. Reduced Fixture Requirements
In multi-axis operations, fewer positioning fixtures are needed to support the workpiece. This increases accuracy because the workpiece can be held in place, reducing the chances of movement.
6. Extended Tool Life
Multi-axis machines control tool wear by changing the cutting angle, allowing tools to last longer and reducing maintenance costs.
7. Mass Production Capability
Multi-axis machines can produce high-precision replicas of machined parts. They are most effective in maintaining consistency in production output quality.
Limitations of Multi-Axis Machining
1. Complex Setup and Programming
The programming and setup of multi-axis machining are relatively complex, especially when dealing with multi-axis synchronous movement, which requires higher operator skills and programming experience. This also increases the initial setup time.
2. Longer Lead Time
Due to the more complex programming methods, lead times may be extended. This can be a disadvantage when production cycles are shorter, as there may not be enough turnaround time.
3. Skill Requirements
Not all technicians can program these machines. Therefore, managing such multi-axis machines requires CNC programming and machine operation training, which may not be easy to obtain.
4. Maintenance Complexity
Maintenance and calibration of multi-axis machines are more complex. Frequent tool changes and calibrations are necessary to maintain machine precision. This adds to the operational complexity and maintenance burden.
