This article will take an in-depth look at 5 axis CNC machining.
The article will bring more detail on topics such as:
This section delves into the essentials of 5-axis CNC machining, scrutinizing its structure, mechanics, and functionality.
While typical CNC machines function along three primary axes—X, Y, and Z—5-axis CNC machines integrate an additional two axes: A and B. These extra dimensions provide the capability to produce more complex and detailed parts with enhanced precision. This technology has seen increased utilization due to its ability to drastically reduce manufacturing time.
The rotating cutting tools in CNC systems swiftly shape the desired geometries with precision. By employing a table that moves and rotates across all five axes, strain on the cutting tools is decreased, which prolongs the CNC machine's operational life. Presented below is an illustration showing a 5-axis CNC machine.
5-axis machining represents a superior evolution from the standard 3-axis CNC method. This sophisticated, computer-guided mechanical technique moves tools across five directions with high accuracy to remove material efficiently, forming parts and components. The process begins with a CAD-designed concept, which is translated into precise CNC codes directing machine operations.
CNC machining provides high-standard results for various applications requiring both horizontal and vertical machine setups, including intricate turned parts.
The multifunctional nature of CNC machines allows for the efficient production of components in one seamless operation, including items like collars, bushings, fittings, fasteners, and spindles, to name a few.
A 5-axis CNC machine is structured with several essential components:
Diamond tools are typically employed for precise applications and feature cutting surfaces covered with diamond particles. Figure 1.3 demonstrates a machine table equipped with a spindle for gemstone cutting, showcasing the diamond tool's motion directions. These tools, specifically crafted for accurate edges, integrate diamond particles across their surfaces.
The selection of tool size correlates with the width of the cut and the desired post-machining surface finish. The diameter of the diamond particles applied to the tool aligns with the tool head's diameter. Primarily functioning along Z, X, and Y axes, the tool’s design facilitates precision. The B and A axes enable precise carvings of curved and arced patterns on workpieces.
For materials like sapphire and marble, which are notably brittle, the processed sizes usually do not exceed 60x60x60 mmÂł. Due to their extreme hardness, an abrasive machining protocol is used, with the diamond tool operating at speeds between 8,000 and 12,000 RPM. The tool's unique shape necessitates horizontal orientation, aligning with the plane of rotation. Below, you'll find the crucial design parameters.
| X, Y, Z linear motion Material size | 100 mm |
|---|---|
| Rotation angle of A axis | 180 degrees |
| Rotation angle of B axis | 360 degrees |
| Spindle Speed | 0 to 18 000 RPM |
| Cutting tool size | Φ(3 – 6)mm by 60mm |
| Material size | 60 by 60 by 60 cubic mm |
Established design principles guide the selection of primary parts and systems at the outset. Initially, the creation of CNC machines involves choosing core components and available systems while innovating new systems for specific needs. Below is an overview of the main components:
The design of a CNC machine encapsulates both its electrical and mechanical frameworks. Mechanically, the parts must be assembled to maintain stability and efficient energy transfer. The supporting frame ensures precise, flexible movement between elements, forming a cohesive apparatus.
The axes movements and spindle are aligned for optimal functionality. Mechanical system parts are designed, assessed, and simulated using Inventor software. An example 3D CAD model of CNC machinery is displayed above. Stepper motors drive the Z, X, and Y axes via ball screws, while timing belts drive the B and A axes. Initially, commercially viable parts were adopted, integrating other components for specific functionalities. B and A axis calibration ensures solid connections, effectively executed with durable materials. Key steps include leveraging timing belts to lessen motor torque and determining dimensions and ratios. Complete machine assembly, axis movement simulations, and component adjustments are achieved through 3D CAD simulations.
The CNC's electrical framework is tailored to support its operation. It uses a DC power setup with variable voltages: 5VDC for control inputs, 24VDC for motors, and 12 to 100VDC for spindle speed regulation. The electrical system's schematic is featured in Figure 1.5 below.
CNC machining relies on subtractive technology to sculpt parts using tools that carve material away until the desired shape is achieved. This design originates from a CAD file, which becomes a guiding G-Code program for the CNC system.
In contrast to most CNC milling apparatus that move on three axes (Z, X, and Y), 5-axis machines utilize additional axes to perform cuts from diversified angles, accommodating more complex layouts. The 5-axis system introduces axes A, B, and C for improved cutting flexibility.
A 5-axis CNC cutter approaches the workpiece from five perspectives. It traverses along Z, X, and Y axes while rotating across A, B, or C axes. Here are the axes and their movements:
With a 5-axis cutting apparatus, the Z, X, and Y axes twist in rotational angles to craft sophisticated designs with superior finishes. Axes A, B, and C freely rotate around Z, X, and Y. The CAD model or machine's configuration decides which extra axes are operated. Costs rise with this 5-axis arrangement due to the sophisticated calibration and automation technologies essential for precise functionality and command execution.
Here are important factors when selecting a 5-axis CNC machining approach:
The CNC control needs abundant processing strength to compute, regulate, and maneuver all moving axes concurrently.
For a 4+1 axis machine, a "look-ahead" function with 200 blocks is needed. Complex 4-axis sequences should aim for 400 blocks. For full simultaneous 5-axis machining, CNC control should have a look-ahead capacity of 1000 blocks or more for fast calculations.
A crucial, yet sometimes overlooked, aspect is the need for sufficient spindle robustness and power. A powerful spindle demands a robust foundation. For smooth cuts, it must withstand stress with a suitable power reserve. Some tasks may restrict those with an 11kW to 15kW spindle limited to 100 Nm torque. Initial savings on such spindles could prove costly.
Verify that the tool-holding arrangements are HSK or BBT to minimize vibration, ensuring optimal fit between the tool holder and spindle, regardless of conditions.
In line with machining needs, keeping a stable feed rate or adjusting to match cutting demands is vital. Thus, machines must adeptly manage and adapt cutting feed rates.
Comprehensive machine tolerance demands meticulous design and construction consideration.
This involves two main phases:
5-axis CNC machining offers enhanced efficiency and reduced error rates compared to more traditional methods. However, rigorous inspection remains necessary. Enhanced productivity is supported by stringent quality controls at every stage, with procedures addressing both documentation and processes.
Quality inspection for 5-axis systems incorporate three levels: tool precision, part validation, and process oversight.
Even with the accuracy of 5-axis systems, thorough inspection is paramount to ensure the final output meets customer expectations. Despite its technological advancement, such methods require consistent monitoring and management.
Effective heat control in the spindle is vital for optimal 5-axis CNC machine performance. By efficiently managing heat, the service life of crucial components is extended, improving overall quality and accuracy. Both spindle housing and nose require adequate cooling to prevent overheating during demanding tasks, which involve quick speeds and extensive machining sessions. For built-in motors housed within spindles, ensure tailored section cooling of both housing and nose.
5-axis CNC machines are uniquely engineered to deliver exceptional precision and machining versatility across a broad range of industries, including aerospace, automotive, medical device manufacturing, and mold making. These advanced CNC machine tools enable simultaneous multi-axis operations, complex part fabrication, and reduced setups, which contribute to shorter production cycles and improved surface finishes. Below, we present some of the leading 5-axis CNC machine manufacturers and their top-rated 5-axis models available in the United States and Canada, helping manufacturers and job shops identify the best solutions for their specific requirements.
The UMC-750SS by Haas Automation is a versatile 5-axis CNC machining center known for its robust construction, which ensures both stability and accuracy during high-speed operations. It offers true simultaneous 5-axis machining, enabling the precise production of complex and intricate parts often required in aerospace and medical applications. This model is equipped with a high-speed, direct-drive spindle for rapid and precise cutting, as well as advanced CNC control integration for easy programming and efficient workflow management. Its generous work envelope and automatic tool changer make it ideal for high-mix, low-volume as well as high-production environments.
The DMU 50 from DMG MORI is a compact 5-axis machining center designed to deliver high-precision part manufacturing across a wide range of CNC milling applications. It features a swivel rotary table and a swiveling milling head for true multi-sided and complex component machining. The high-performance spindle provides substantial torque and spindle speed for efficient, accurate, and flexible cutting—critical for industries demanding intricate geometry work. Advanced CNC control systems and proprietary DMG MORI software further enhance its machining capabilities, allowing for seamless machine automation, tool management, and process monitoring. These features help address user needs for flexibility, production efficiency, and user-friendly operation.
The VARIAXIS i-800 by Mazak is a high-performance 5-axis machining center that combines versatility with continuous productivity. It includes a tilting rotary table and a robust, high-speed spindle for simultaneous 5-axis machining of complex parts, making the machine suitable for advanced mold making, prototype manufacturing, and precision engineering. This model is equipped with Mazak's SmoothX CNC control for advanced multi-axis programming, real-time monitoring, and enhanced process optimization. Features like automatic tool changers, tool length measurement, and adaptive spindle control not only boost operational efficiency but also reduce labor costs, setup times, and cycle times—key considerations for machining job shops and OEMs seeking to improve profitability and machining flexibility.
The MU-4000V-L by Okuma is a vertical 5-axis machining center renowned for its high rigidity, precision manufacturing capability, and advanced automation options. It offers a spacious work envelope and a tilting trunnion table for highly versatile machining of various part sizes, from small components to large workpieces. Okuma’s exclusive Thermo-Friendly Concept minimizes thermal deformation, ensuring consistently tight tolerances and repeatable accuracy across long production runs. The model also features Okuma’s INTELLIGENT Technology suite, which includes high-speed spindles, adaptable tooling systems, and integrated process control for improved productivity, machine uptime, and ease of use—appealing to manufacturers requiring uncompromising accuracy and consistent process reliability.
The Robodrill α-D21MiB5 by FANUC is a compact, high-speed 5-axis machining center valued for its efficiency, repeatability, and precision in small-to-medium part production. It features a built-in motor spindle and an advanced simultaneous 5-axis drive system, enabling rapid and accurate machining ideal for electronic component manufacturing, medical device prototyping, and automotive parts. Powered by FANUC’s industry-leading CNC control platform, users benefit from intuitive programming, advanced tool path optimization, and remote monitoring capabilities that streamline workflow and boost shop floor productivity. In addition, the machine offers an automatic tool changer and efficient chip management system, both of which help reduce setup times and optimize high-mix part production.
When selecting the best 5-axis CNC machine for your business, consider key factors such as maximum part size, spindle speed, available CNC software, automation compatibility, precision requirements, and support services offered by the manufacturer. Most leading CNC machine builders provide a diverse range of models and options—such as integrated pallet changers, coolant management systems, and multi-tasking solutions—to meet the specific needs of different industries and applications. For the most accurate and current information on specific models, technical specifications, pricing, and after-sales support, it is recommended to consult directly with the manufacturers or their authorized distributors. Additionally, evaluating customer reviews, case studies, and third-party benchmarking can help guide your CNC machinery purchase decision to maximize return on investment and operational efficiency.
Understanding the different types of 5-axis CNC machines is crucial when selecting a system for high-precision machining and complex part manufacturing. The fundamental distinction between these machine types lies in the location of their rotational axes, directly impacting machining flexibility, accuracy, and material handling capabilities. In some 5-axis CNC machines, such as trunnion and double rotary table designs, rotation is achieved by moving the work table, which repositions the workpiece during machining. In other configurations, such as swivel or articulating head machines, the rotation comes from the tool head, allowing the material to remain stationary. Swivel head machines are highly effective for large and heavy workpieces since the mass stays fixed, ensuring greater stability during high-speed milling and multi-axis contouring. In contrast, table-moving designs offer enhanced speed, accuracy, and repeatability for lighter components and complex geometries.
This advanced 5-axis CNC machine features a B-axis equipped with a full 360-degree rotary table positioned underneath the workpiece, delivering exceptional flexibility for multi-sided machining. The machine provides a substantial workspace with a diameter of 50 inches and a height of 50 inches, making it ideal for large-scale components common in aerospace, automotive, and energy applications.
This type is especially suited for manufacturing components with intricate angled holes, slots, or features—such as turbine housings, impellers, and custom tooling—where precise orientation is required on the outer diameter (OD) or internal diameters. Thanks to its design, repositioning among multiple machining locations requires movement in just a single axis, compared to the two or more axes demanded by other 5-axis machines for similar tasks on cylindrical components. This reduction in necessary movements not only improves process repeatability but also decreases potential for cumulative positioning errors.
Due to the machine's ability to minimize the movement of the part, it outperforms other designs in handling oversized or elongated materials and offers unmatched performance in tall part machining. In trunnion-style systems that rotate the table along both A and B axes, the workspace is often limited by axis clearance. With the rotary table and pivoting spindle head configuration, however, the design allows for efficient heavy-duty cutting, long tool reach, and superior surface finishing of tall cylindrical parts with fewer clamping or setup changes—a significant advantage for high-mix, low-volume production and custom manufacturing.
This 5-axis CNC design utilizes both an A-axis and a B-axis rotary table, enabling highly flexible part orientation. A key advantage lies in its ability to orient the part or fixture over a wide range of angles for advanced contouring and simultaneous machining operations, such as multi-face drilling and complex surface milling. For programmers, it’s vital to know the A-axis table face's position relative to the B-axis pivot point to ensure collision-free tool paths and accurate feature alignment.
This machine excels at machining components that require full access around the OD, especially where concentric features, indexable rings, or evenly spaced holes must align precisely with the spindle axis. Double rotary table systems are prominent in industries such as precision medical device manufacturing, optics, and high-precision prototyping, where acute angular positioning and optimal surface finish are paramount.
However, open table designs like this can pose challenges for clamping and supporting large workpieces. Material size and mass are restricted by the limits of the rotary axes and the load capacity of the horizontal table. Despite these constraints, the double rotary table format offers broad XYZ travel, allowing for the use of extended tools or custom fixtures to machine at severe angles without compromising dimensional accuracy. This configuration supports advanced 5-axis simultaneous machining, significantly reducing secondary setups, which is highly valuable in lean manufacturing environments.
The trunnion setup, also referred to as a Table-Table configuration, integrates both rotary axes directly into the trunnion table while keeping the machining head stationary. This arrangement closely mirrors traditional three-axis CNC milling with added benefits, offering a familiar workflow for operators transitioning to multi-axis production. The dual rotary axes are predominantly used for precise positioning and orienting the workpiece, streamlining complex 3D machining and five-sided part access.
Trunnion tables offer unmatched undercut capabilities and allow greater tilt angles than many swivel head machines, making them ideal for complex mold making, injection mold tooling, and aerospace brackets. The design maximizes the available work envelope—since the table's ability to tilt and lock allows the linear X, Y, and Z axes to maintain the broadest possible travel for large or odd-shaped components.
Additionally, the stationary head enables the use of belt-driven or gear-driven spindles, providing high torque at lower RPMs. This is optimal for aggressive metal removal, roughing operations, and cutting dense materials such as titanium and hardened alloys frequently found in aerospace and automotive manufacturing. Because the head does not move, there’s significantly reduced risk of misalignment, guaranteeing higher repeatability and machining accuracy for close-tolerance parts.
This versatile 5-axis CNC machine can be configured as either a head-head (both rotational axes in the spindle head) or a head-table (one axis in the head, one in the table) layout. In both cases, the machine head performs the majority of rotational movement while the worktable remains fixed or partially rotates. These configurations excel at machining extremely heavy or oversized workpieces without introducing vibration or instability, as the static table ensures maximum structural support throughout the machining process.
Swivel head machines are commonly selected for industries requiring heavy-duty cutting of large aerospace components, heavy-duty mold bases, or complex prismatic parts in energy and defense manufacturing. The stationary table not only handles heavier payloads but also enables machining of larger part blanks and castings. Machining heads with advanced articulating spindle designs facilitate the use of shorter, rigid cutting tools, which results in reduced tool deflection and improved surface finish during simultaneous 5-axis cutting and multi-axis profiling.
Moreover, these machines offer enhanced flexibility for multi-face machining and allow efficient tool changes, helping manufacturers minimize production lead times and maximize throughput. When choosing the optimal 5-axis machine, consider key factors such as part size, weight, material type, complexity of machining operations, and required tolerances to select the best configuration for your business needs.
This chapter will explore the applications and advantages of 5-axis CNC machining.
Originally, 5-axis CNC machines were primarily used in the aerospace industry, but they are now widely adopted across various sectors. A 5-axis CNC machine can replace a 3-axis CNC machine, offering smoother finishes and greater efficiency. It reduces cycle times and minimizes the need for manual tool changes or component repositioning. In a 3-axis CNC machine, repositioning the component is necessary to machine all its faces, which can introduce alignment issues and human error. A 5-axis CNC machine eliminates these challenges by providing easy access to all faces of the component.
CAM and CAD software for 5-axis CNC machines can be highly advanced, offering numerous programming options. These tools often include collision avoidance features and post-processors for seamless machine integration. With the right setup, these programs can even facilitate "lights-out" CNC machining, where the machine operates unattended. 5-axis CNC machining is particularly useful for creating complex 3D shapes and performing traditional machining on angled or irregular surfaces. Some common industries that benefit from 5-axis CNC machining include:
Aerospace Applications: In the aerospace industry, 5-axis CNC machining is valued for its ability to produce contoured edges and smooth surfaces. Aerospace components are often geometrically complex, and the precision of a 5-axis CNC machine is crucial for achieving intricate details and interior cuts. Additionally, the machine's capability to complete a component in a single pass without repositioning enhances accuracy and efficiency.
Medical Device Manufacturing: In the medical field, 5-axis CNC machining offers significant advantages for manufacturers of implants, devices, and other precision parts. The high precision of 5-axis CNC machines meets the stringent standards of healthcare production. These machines are capable of efficiently producing small, intricately detailed components, saving both time and money through improved accuracy and streamlined processes.
Military Applications: 5-axis CNC machines are frequently used to manufacture precision parts for military devices. In addition to their aerospace applications, they produce components for submarines, compressor blades, turbines, smart weapons, sensors, high-performance engine parts, stealth technology, and even nuclear weapons. While not all components are military-related, nearly half of all 5-axis CNC machines are purchased for projects or contracts involving the American government.
Energy Equipment: 5-axis CNC machines are well-suited for producing specific and detailed parts required by the energy sector. When working with particularly tough or abrasive materials, these machines provide stability, making it easier to shape and cut the material. They also enhance process efficiency and reduce tool wear.
Additional industries that benefit from 5-axis CNC machining include pharmaceuticals and food processing.
Five-axis CNC machining facilitates the cost-effective production of intricate designs. The advantages of adopting five-axis CNC machining include:
With a five-axis CNC machine, you can access all surfaces of a component, except for the bottom and clamping areas. Unlike a three-axis CNC machine, which requires multiple setups and manual rotations to achieve complex geometries, a five-axis CNC machine completes the task in a single setup. This reduces the number of setups needed and saves time.
The additional movements provided by five-axis CNC machining allow for the creation of intricate designs and shapes. This capability enables machining of arcs and angles that previously required multiple setups and special fixtures. With five-axis CNC technology, complex fixtures are no longer necessary, as the part is held in place and rotated during a single process to achieve the desired geometry.
Every time a component is removed from a machine, precise alignment is often lost, impacting quality. Unlike three-axis CNC machining, five-axis CNC machining improves accuracy by allowing the entire job to be completed in a single setup. This method maintains precision and quality while producing complex shapes without compromising on the required accuracy.
In five-axis CNC machining, the cutting tool remains tangential to the cutting surface, which allows for shorter cycle times. This approach helps in removing more material with each pass of the tool, leading to increased efficiency and reduced machining time.
The additional fourth and fifth axes in five-axis CNC machining improve orientation and bring the component closer to the cutting tool. This allows for the use of shorter tools, which are less prone to vibrations at high cutting speeds, resulting in superior surface finishes. Additionally, this setup reduces machining time compared to a three-axis CNC machine, where smaller cuts are often necessary to achieve a good surface finish, leading to longer lead times.
While 5-axis CNC machining offers numerous benefits, it also has some drawbacks, including:
5-axis CNC machines and their associated software often require a higher initial investment compared to standard 3-axis machines. The overall cost of acquisition and maintenance can be significantly higher, with maintenance sometimes being more complex.
5-axis CNC machining involves two additional rotational movements beyond the three linear axes, making it more complex than 3-axis machining. Coordinating the movement of all axes to avoid collisions and ensure precise interpolation can be challenging. Complex programming is required to achieve optimal surface quality and machining precision, which may necessitate the expertise of a skilled programmer.
Operating a 5-axis CNC machine requires advanced skills for setup, programming, and operation. Skilled technicians are essential to manage the complexity of the technology effectively.
Despite these challenges, the advantages of 5-axis CNC machining generally outweigh the drawbacks. However, it is important to carefully consider the various challenges associated with adopting this advanced technology.
Travels and Available Capacity
Spindle Machining using CNC
Tool changer
Feed rates
5 Axis Size
5 Axis CNC Machining Electrical
Some considerations when maintaining 5 axis CNC machines are:
The primary advantage of 5-axis machining is its capability to produce intricate and complex parts with high precision. This efficiency significantly reduces production time from start to finish. By allowing the cutting tool or work table to rotate, 5-axis machining minimizes the risk of collisions and efficiently handles various part geometries without the need for reprogramming or additional machining.
Most CNC machine centers are based on the traditional 3-axis configuration, consisting of the X, Y, and Z axes. The 5-axis configuration expands on this by incorporating two additional axes, enhancing the tool's movement and flexibility.
5-axis machines typically include the following five-axis configurations:
Double Swivel Head Form - With the double swivel head form, two rotation coordinates control the direction of the cutter axis directly.
Droop Swivel Head Form - The droop swivel head form has the two coordinate axes at the top of the cutter with the rotational axis not perpendicular to the linear axis.
Double Swivel Table Form - In the double swivel table form, the two rotation coordinates control the space rotation, directly.
Droop Table Form - With the droop table form, the two axes are on the table, while the axis of rotation is not perpendicular to the axis.
One Swing, One Rotate Form - The one swing, one rotate form has two rotation coordinates with one on the cutter and one on the workpiece.
A 5-Axis CNC machine offers industries the chance to undertake jobs that they were formerly unable to complete. For manufacturers who presently use 3-Axis CNC machining, the advancement to a 4+1 or even full 5-axis CNC machine is the next logical step in their investment and production planning. Due to the price of such machines, nevertheless, it is advised that customers fully understand which procedures best meet the specific production requirements. There is also a need to pick the right CNC machine tool to realize the profitability and efficiency of production completely.
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