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CNC machining offers advantages such as high precision, high speed, and high quality, and can efficiently process various plastic and metal materials. By increasing the number of machining axes on a milling machine, it can significantly reduce part manufacturing time and enable the production of complex components.
However, when faced with two advanced technologies—3+2 Axis CNC Machining and 5 Axis CNC Machining—many people wonder: What exactly are the differences between them? And how can one make the best choice for their project?
This article will analyze both technologies, starting with their fundamental definitions. We will then examine their capabilities, advantages, disadvantages, and application scenarios. Finally, we will conduct a multi-dimensional comparison between 3+2 Axis CNC Machining and 5 Axis CNC Machining, providing you with a clear technical selection guide.
1. What is 3+2 Axis CNC Machining
3+2 Axis CNC Machining, also commonly referred to as five-axis orientation machining or positioning five-axis machining, is a method that leverages the capabilities of five-axis machine tools to perform operations similar to three-axis machining. The manufacturing process of 3+2 Axis CNC Machining incorporates additional rotary axes. These axes enable the clamped workpiece to rotate on the A-axis and C-axis (or A-axis and B-axis) while the milling machine continues machining along the conventional X, Y, and Z axes.
For better understanding, we break it down into “3-axis” and “2-axis”:
“3-axis”: Refers to traditional three-axis machining, where the tool moves along three linear axes (X, Y, Z) to perform cutting operations on the workpiece.
“2-axis”: Refers to the two rotary axes on the CNC machine (typically the A-axis and B-axis, or A-axis and C-axis).
Core Principle of 3+2 Axis CNC Machining
It does not involve continuous simultaneous movement of all five axes during cutting. Instead, the cutting tool is first fixed at a specific tilt angle using the two rotary axes. Cutting then proceeds along the linear axes—similar to a traditional three-axis machine—while maintaining this locked tilt angle.
Key Features and Advantages of 3+2 Axis CNC Machining:
Single-Setup Machining: Unlike traditional 3-axis machines requiring multiple re-setups to machine different angles, 3+2 Axis CNC Machining enables processing of multiple surfaces in a single setup. This reduces setup time and eliminates errors caused by repeated re-setups.
Shorter Tooling: By tilting the workpiece, tools can approach surfaces at more perpendicular angles, enabling the use of shorter, sturdier cutting tools. This reduces tool vibration and deflection, allowing higher cutting parameters, achieving superior surface finish, and extending tool life.
Machining complex geometries: It enables processing of side walls, inclined holes, and beveled surfaces on complex parts inaccessible to 3-axis machines.
Cost-effectiveness: Compared to 5-axis CNC machining, 3+2-axis CNC machining requires simpler programming and lower demands on machine tools and control systems, making it a more cost-effective solution for complex part machining in many cases.
Limitations of 3+2 Axis CNC Machining
3+2 Axis CNC Machining typically employs a single fixed angle. When transitioning from one machining area to another requiring a different angle, the machine must halt cutting, drive the rotary axis to reposition at the new angle, and re-clamp before resuming the next machining phase.
This not only increases programming complexity but may also cause toolpath overlap, extending overall processing time. Therefore, compared to 5-axis CNC machining, 3+2-axis CNC machining may lack sufficient flexibility for processing complex workpieces.
Applications of 3+2 Axis CNC Machining
3+2 Axis CNC Machining fundamentally operates as a three-axis machining process, making it more suitable for planar machining and relatively simple three-dimensional operations.
Mold Manufacturing: Deep cavity molds, multi-angle feature molds.
Polyhedral Part Machining: For box-type, disc-type, or valve-body components requiring machining on multiple faces (e.g., five faces), 3+2 Axis CNC Machining is an ideal solution.
Angled Hole and Bevel Machining: Parts often feature angled holes or bevels not parallel to the spindle axis. For high-precision inclined holes, 3+2 Axis CNC Machining can align the hole's centerline perfectly parallel to the spindle for drilling, reaming, or boring operations. Similarly, it can position bevels perpendicular to the tool for finishing, achieving optimal surface finish.
In summary, the application scenarios for 3+2 Axis CNC Machining revolve around “multi-angle positioning.” When your parts involve multiple machining directions, deep cavities, inclined features, and demand high precision, rigidity, efficiency, and cost-effectiveness, 3+2 Axis CNC Machining is your ideal solution.
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What is 5-Axis CNC Machining?
5-Axis CNC Machining refers to a CNC machine tool capable of coordinating simultaneous motion across five coordinate axes (three linear axes and two rotary axes), enabling continuous cutting of workpieces with complex geometries.
Core Concept of 5-Axis CNC Machining
The core concept of 5-axis CNC machining is five-axis simultaneous motion. In true 5-axis CNC machining, five axes of motion (typically X, Y, Z, A, B or X, Y, Z, B, C) move synchronously under precise computer program control. This enables the tool to:
- Continuously traverse complex surface paths while maintaining optimal cutting conditions.
- Achieve superior surface finish by progressively adjusting angles to engage the tool's flank rather than the cutting edge.
Key Features and Advantages of 5-Axis CNC Machining:
Capability for Complex Surface Machining: This represents the core advantage of 5-axis CNC machining. It enables single-setup, high-precision machining of parts featuring complex free-form surfaces, such as impellers, stator discs, propellers, human skeletal structures, and high-precision molds.
Exceptional Machining Efficiency: Unlike 3+2-axis CNC machining, 5-axis CNC machining eliminates frequent pauses and repositioning. Its continuous toolpaths significantly reduce processing time.
Optimal Cutting Position: Through five-axis simultaneous control, the tool is always positioned at the most efficient cutting angle, achieving higher material removal rates.
Exceptional machining accuracy and surface finish: Eliminates multiple setups, ensuring positional accuracy across all machined surfaces. Continuous 5-axis machining produces exceptionally smooth, seamless surfaces.
Limitations of 5-Axis CNC Machining
High equipment investment and operational costs: High-quality 5-axis machining centers typically carry significant price tags. Their complex machine structures demand higher maintenance and calibration requirements.
Complex programming demands skilled technicians: Technicians must not only define tool tip paths but also precisely control tool axis orientation, requiring extensive knowledge and experience.
Compared to 3+2 Axis CNC Machining, 5 Axis CNC Machining exhibits slightly lower spindle rigidity.
Applications of 5-Axis CNC Machining
Aerospace: Aircraft structural components such as wing spars, ribs, and fuselage frames; engine core components including disk blades, blades, and casings.
Automotive Industry: Engine cylinder heads and blocks, turbochargers, prototype vehicles and concept parts.
Energy and Marine Sector: Hydro turbine blades, wind power equipment, pumps and valves.
Medical Devices: Skeletal implants like artificial joints (hip, knee), bone plates; surgical instruments and equipment.
In summary, when your product features complex freeform surfaces, requires maintaining high-precision spatial relationships across multiple angles, possesses intricate structures, and demands extremely high accuracy, 5-Axis CNC Machining is your ideal solution.
Side-by-Side Comparison of 3+2 Axis CNC Machining and 5-Axis CNC Machining
CNC Machining Method | 3+2 Axis CNC Machining | 5 Axis CNC Machining |
Core Principle | Oriented Machining | Interlinked Machining |
Processing Method | Indexing, Positioning, Locking, Machining | Continuous, synchronized, smooth motion |
Advantages | 1.Single setup for multi-faceted machining 2.Enables use of shorter, more rigid cutting tools 3.High surface finish quality
| 1.Capable of machining complex continuous free-form surfaces 2.Extremely high machining efficiency 3.Achieves perfect surface quality 4.Solves complex spatial geometric problems |
Limitations | 1.Low machining efficiency due to frequent positioning pauses 2.Programming is more complex than three-axis systems | 1.High investment in equipment and software 2.Complex programming with high demands on engineers 3.High maintenance and operational costs |
Applicable Part Types | 1.Polyhedral housings and valve bodies 2.Parts featuring inclined holes/beveled surfaces 3.Deep cavity molds 4.Roughing/semi-finishing for five-axis machining | 1.Impellers, impeller discs, propellers 2.Aerospace structural components 3.High-precision mold cavities 4.Medical implants |
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In summary, 3+2 Axis CNC Machining: Five-axis positioning with fixed-angle machining after indexing solves the “positioning” challenge for complex angles. 5-Axis CNC Machining: Simultaneous multi-axis movement resolves the “path” issue for complex surfaces, enabling complete machining in a single setup for exceptional efficiency.
If you require CNC machining services, contact us immediately! Supro is a CNC machining manufacturer based in China, equipped with 80 3-axis, 4-axis, and 5-axis CNC machines. We offer over 120 types of metal and plastic materials, with all production processes completed in-house. We provide professional CNC machining services and online technical support. Whether you require rapid prototyping or batch production of metal/plastic parts, we deliver comprehensive manufacturing solutions!
