Modern manufacturing industry places increasingly higher demands on precision and production efficiency. Multi-axis technology in CNC turning is revolutionizing the way complex metal parts are made. Traditional three-axis lathes often require multiple repositionings of the workpiece. Multi-axis machines eliminate this issue by enabling machining from multiple directions during a single setup.
The development of numerical control systems has enabled the creation of lathes capable of operating simultaneously on five or more planes. Multi-axis machining combines turning and milling functions in one machine. This solution reduces production time by up to 70% compared to conventional methods. Manufacturers of aerospace, medical, and automotive parts especially appreciate these capabilities.
The application of multi-axis technology translates into a measurable increase in companies’ competitiveness. Reducing the number of clamping operations improves the dimensional accuracy of finished components. Analysis of the production process shows significant savings in time and materials. Modern multi-axis lathes achieve tolerances at the level of ±0.005 mm.
Increased dimensional accuracy and machining repeatability
The precision of execution is a key parameter for assessing the quality of part production. CNC multi-axis lathes provide dimensional stability at an unprecedented level. Advanced control systems monitor tool position in real time. Automatic tool wear compensation maintains consistent quality throughout the entire production cycle.
Elimination of errors related to multiple workpiece clamping
Each re-clamping of the workpiece introduces a potential source of inaccuracy. Traditional methods often require three or four repositionings for complex shapes. Single-setup machining eliminates cumulative positioning errors. The operator does not need to manually set the part at different angles.
Main sources of errors in conventional machining:
- Inaccuracy of repositioning in the clamping fixture
- Mechanical deformations during workpiece clamping
- Backlash in machine drive transmission components
- Thermal expansion of components during prolonged operation
- Wear of base surfaces on fixtures and clamps
Multi-axis systems eliminate most of these problems through continuous machining without interruptions. The part remains clamped in the same setup from start to finish of the process. The computer controls all tool movements with micrometer precision. Modern measuring sensors verify dimensions directly on the machine.
Maintaining the Optimal Tool Angle Throughout the Entire Process
The cutting geometry directly affects the quality of the machined surface. Multi-axis control allows adjusting the tool orientation to the currently machined section. The tool always operates at the most efficient rake angle. Minimizing cutting forces extends tool life and improves surface finish.
Constantly maintaining optimal contact geometry reduces system vibrations. Vibrations are the main cause of surface roughness. Five-axis systems automatically correct positioning during machining. Special algorithms calculate the most favorable motion trajectory for each contour segment.
Achieving Tighter Tolerances Compared to Three-Axis Machines
The differences in accuracy capabilities between systems are a key factor in technology selection. Three-axis lathes typically achieve tolerances ranging from ±0.05 mm to ±0.1 mm. Multi-axis machines maintain accuracy from ±0.005 mm to ±0.01 mm. A tenfold improvement in precision opens new design possibilities.
| Parameter | Three-Axis Machining | Multi-Axis Machining |
|---|---|---|
| Typical dimensional tolerance | ±0.05 – 0.1 mm | ±0.005 – 0.01 mm |
| Number of setups for a complex part | 3-5 operations | 1 operation |
| Part setup time | 15-30 minutes | 5-10 minutes |
| Dimensional repeatability | Average | Very high |
| Capability to machine complex angles | Limited | Full |
Industries requiring the highest precision particularly benefit from multi-axis technology. The aerospace industry uses components with micrometer tolerances. The medical sector needs perfectly fitted implants and prosthetics. Motorsport demands parts with minimal weight and maximum durability.
Shortening Order Fulfillment and Production Cycle Time
The speed of order completion directly affects the competitiveness of a manufacturing company. Multi-axis technology drastically reduces the time needed to produce a single part. Simultaneous operation of multiple axes shortens the machining cycle length. Automation of the process eliminates waiting for operator intervention.
Reduction of Downtime During Part Setup Changes
Downtime accounts for a significant portion of total production time in traditional systems. Manually repositioning the workpiece between operations takes from several to dozens of minutes. Multi-axis machines perform all procedures without stopping work. Eliminating downtime increases the effective productivity of the production line.
Analysis of working time utilization shows dramatic differences. A conventional lathe operates actively about 60% of the shift time. The remaining 40% is consumed by setup and repositioning. A multi-axis system achieves a utilization rate exceeding 85%. This difference directly translates into production throughput.
The Ability to Complete a Part in One Setup
Complete machining without repositioning is a fundamental advantage of multi-axis systems. A single clamping allows performing all turning, drilling, and milling operations. The tool has access to five or six faces of the workpiece simultaneously. The finished part leaves the machine without needing additional procedures.
Operations performed in one cycle:
- Turning external and internal surfaces
- Countersinking and drilling holes at any angles
- Milling pockets, recesses, and slots
- Threading on transverse axes
- Creating undercuts and angled surfaces
- Engraving markings and serial numbers
The ability to carry out all operations in one setup changes the economics of small-batch production. Machine setup costs are spread over the entire production volume. Short runs become economically viable. Prototyping proceeds much faster than in conventional systems.
Manufacturers of complex parts save up to 50% of order fulfillment time. Shortening delivery cycles improves customer relationships. The ability to respond quickly to urgent orders provides a competitive advantage. Companies offering short lead times gain greater market share.
Economic Savings in the Production Process
Production economics determines the profitability of a manufacturing enterprise. Investment in multi-axis technology pays off by reducing operating costs. Total cost of ownership analysis clearly shows an advantage over traditional systems. Savings are realized in many areas of the production process.
Reduction of Cutting Tool Wear
Tools represent a significant portion of machining costs. Optimal cutting angles in multi-axis systems extend tool life by up to 40%. Lower cutting forces reduce mechanical wear. Better heat dissipation protects tool coatings from overheating.
Multi-axis control eliminates unnecessary air moves. Tool path optimization shortens the total travel distance. Every millimeter of saved movement translates into longer tool life. Monitoring systems automatically change the tool at the optimal moment.
Optimization of Material Usage and Waste Reduction
The cost of raw material often constitutes the dominant part of production expenses. Precise multi-axis machining minimizes material allowances. Parts can be made from bars with smaller diameters. Waste reduction lowers both material purchase costs and chip disposal expenses.
Modern CAM systems optimize part placement on blanks. Machining process simulation helps avoid collisions and programming errors. Fewer production rejects translate into raw material savings. Some plants report a 25% reduction in waste after implementing multi-axis technology.
Reduction of Machine Operator Labor Costs
Process automation reduces the demand for manual labor. A single operator can supervise multiple multi-axis machines simultaneously. Operating conventional lathes requires constant presence at each station. Multi-axis systems run independently for many hours without intervention.
Operator tasks for multi-axis machines:
- Loading material at the start of the cycle
- Inspecting the first piece after program startup
- Periodic replacement of worn tools according to system indications
- Checking dimensions of random parts during the batch
- Unloading finished parts and packaging
The reduction in direct labor lowers unit production costs. Less demand for skilled operators simplifies workforce management. Automatic measurements on the machine eliminate the need for inspections at separate stations. Total human labor time per part decreases by up to 60%.
Lower Costs for Clamps and Mounting Fixtures
The versatility of multi-axis systems reduces the need for specialized tools. Standard clamps accommodate a wide range of shapes. Traditional manufacturing often requires dedicated fixtures for each type of part. The cost of designing and producing a fixture can exceed several thousand PLN.
The flexibility of mounting in multi-axis machines allows for simpler solutions. Programmable stops and positioners replace complex mechanisms. Inventory and storage of clamps generate additional costs. Fewer specialized tools free up the company’s working capital.
Tip: Before purchasing a multi-axis lathe, carefully analyze the production structure. The technology offers the greatest benefits when manufacturing complex parts in medium batches. Simple cylindrical parts can be produced more efficiently on conventional machines.
Capabilities for Machining Advanced Geometries and Shapes
The development of mechanical designs demands increasingly complex forms. Multi-axis technology in CNC turning enables the creation of geometries impossible to achieve with traditional methods. The freedom of tool movement across multiple planes opens new design possibilities. Engineers can optimize shapes without technological constraints.
Performing Deep Undercuts and Complex Cavities
Undercuts pose challenges for conventional machining methods. Multi-axis systems solve the problem by tilting the tool at the appropriate angle. Deep interiors and pockets become accessible to the cutting edge. The ability to machine from the side eliminates geometric limitations of standard lathes.
Special ball-end mills create intricate internal shapes. Simultaneous control of five axes allows smooth transitions between surfaces. Designers use this freedom to create lightweight structures with high rigidity. Undercuts reduce part weight while maintaining mechanical properties.
Machining Surfaces at Various Angles Without Repositioning
Parts with complex plane orientations require multiple operations in traditional systems. Multi-axis machines automatically rotate the workpiece to the required position. Inclined surfaces, angled holes, and cross threads are produced in a single cycle. Eliminating repositioning shortens production time and improves precision.
The ability to work at any angle expands the range of machinable materials. Difficult-to-cut alloys can be machined under optimal conditions. The proper tool rake angle facilitates chip removal. Machining composite materials requires precise control over cutting direction.
Production of Elements with Irregular and Complex Contours
Organic shapes and natural curves are the specialty of multi-axis machining. Sculpting freeform surfaces proceeds smoothly without visible transitions. Turbochargers, pump impellers, and turbine blades require precise profile replication. Maintaining curvature continuity ensures proper aerodynamic properties.
Applications of advanced geometry machining:
- Turbine blades for variable pitch aircraft engines
- Medical implants tailored to patient anatomy
- Injection molds for designer packaging production
- Components for automotive sports equipment
- Design prototypes of industrial products
Computer simulation of the process allows verification before machining begins. Advanced CAM software generates optimal tool paths. The post-processor adapts the program to the specifics of each machine. Collision operations are detected and eliminated during preparation.
Geometric flexibility shortens the development cycle of new products. Designers can quickly verify prototypes in real material. Design modifications do not require new tooling preparation. Iterative shape refinement proceeds efficiently and economically.
Tip: Programming complex surface machining requires advanced CAM software. Investing in professional programming tools pays off by reducing production setup time. Operator training in CAD/CAM systems is a key element of technology implementation.
CNC Turning Services at CNC Partner
CNC Partner specializes in professional machining of rotational solids using advanced numerical control technologies. The company combines many years of experience with a modern machine park, handling both single orders and serial production of components with varying complexity levels. The facility serves clients from Poland and European Union countries, producing precise parts for the automotive, aerospace, medical, and electronics industries.
High quality workmanship and punctuality have been company priorities since its inception. CNC Partner operates modern CNC lathes equipped with driven tools, enabling comprehensive part machining in a single setup. Quality control of each component guarantees compliance with the highest precision standards.
Comprehensive Machining Service Offer
CNC Partner provides a full range of CNC machining services for metals and plastics. CNC turning is one of the company’s core specialties, complemented by additional technological processes. The integration of various machining methods allows for the completion of entire projects without the need to involve additional contractors.
Available machining technologies:
- Precision turning of rotating parts with driven tools
- CNC milling on modern machining centers
- Wire Electrical Discharge Machining (WEDM) for materials up to 64 HRC hardness
- CNC grinding with surface finish up to Ra 0.63
Advanced CAM software enables optimization of machining strategies for complex geometries. Process simulation before production eliminates errors and shortens lead times. The company works with materials ranging from steel up to 54 HRC hardness, through aluminum and brass, to technical plastics.
CNC Metalworking Services
Fast Turnaround and Flexible Approach
CNC Partner stands out with quick quotation times and a flexible production schedule. Order quotes are prepared within 2 to 48 hours after receiving an inquiry. Order fulfillment ranges from 3 to 45 days, depending on project complexity and production batch size.
The company delivers across Poland within a maximum of 48 hours. Larger contracts are handled with their own transport directly to the client’s premises. Positive customer reviews confirm the high quality of services provided and timely order fulfillment.
Contact CNC Partner to receive a quote for CNC turning services tailored to your individual production needs. A team of experienced specialists will provide technical support at every stage of the project.
Improving the Surface Quality of Machined Parts
Surface roughness and texture affect the functional properties of mechanical components. Multi-axis machining provides a better finish than conventional methods. Controlling multiple parameters simultaneously minimizes defects. Finished parts often do not require additional finishing operations.
Minimizing Tool Vibration and Achieving Better Finish
Vibrations are the main source of surface roughness on machined surfaces. Short tools in multi-axis systems offer greater rigidity. Access from multiple directions allows for optimal tool overhang lengths. Reduced vibrations directly translate into smoother surfaces.
Simultaneous control of feed rate and spindle speed eliminates harmonic vibrations in the system. Advanced algorithms dynamically adjust parameters to current cutting conditions. The system monitors drive loads and prevents resonance. Process stability ensures consistent quality throughout the entire production series.
Reducing the Need for Additional Finishing Operations
The high surface quality achieved through multi-axis machining often eliminates the need for grinding. The Ra roughness parameter reaches values below 0.4 μm. Such a finish meets the requirements of most industrial applications. Skipping grinding operations shortens production cycles and reduces costs.
A reduced number of technological operations lowers the risk of part damage. Each additional setup increases the likelihood of defects. Complete machining in one cycle minimizes potential errors. Quality control is simplified by eliminating multi-step processes.
Factors Affecting Surface Quality:
- Proper selection of tool geometry for the material being machined
- Maintaining an optimal approach angle throughout the cycle
- Thermal stability of the machine during prolonged operation
- Quality of machine axis guides and drive systems
- Precision of cooling and lubrication systems in the cutting zone
Improved surface finish extends the operational durability of components. Smooth surfaces reduce friction in mechanical joints. Lower roughness limits fatigue crack initiation. Parts with better surface quality require replacement less frequently.
Tip: Regular machine maintenance is essential to maintain high-quality machining. Bearing, guide, and ball screw condition checks should be performed according to the manufacturer’s recommendations. Vibration monitoring detects component wear before machining parameters deteriorate.
FAQ: Frequently Asked Questions
When does multi-axis machining in CNC turning become economically viable?
Multi-axis technology provides the greatest benefits when producing complex parts requiring machining from multiple sides. Cost-effectiveness appears with batches of 50 to 100 pieces of components with complex geometry. Simple cylindrical parts are better produced on conventional lathes. The key factor remains the complexity of the shape and the number of required operations.
The investment pays off faster when producing parts that previously required three or more setups. Eliminating additional fixtures reduces cycle time by up to 70%. Companies specializing in aerospace, medical, or motorsport automotive industries achieve the shortest payback periods. Cost analysis should consider savings in material, tooling, and operator labor time.
What materials can be machined on multi-axis CNC lathes?
Multi-axis systems handle virtually any material suitable for mechanical cutting. Stainless steels, aluminum, titanium, and brass are among the most commonly machined materials. Advanced control systems enable precise machining of difficult-to-cut nickel and cobalt alloys. The ability to optimally set the tool angle facilitates working with low machinability materials.
Technical plastics also respond well to multi-axis machining with excellent results. PEEK, polycarbonate, and polyacetal used in medical applications require gentle tool handling. Simultaneous control of multiple axes minimizes stresses in the material. Fiber composites require a special approach to cutting direction. Technical ceramics are machined at significantly lower feed rates than metals.
How long does it take to learn multi-axis machining programming?
An operator familiar with basic CNC programming needs about three to six months to master a multi-axis system. Previous experience with three-axis machines significantly shortens training time. Knowledge of CAM software capable of generating five-axis toolpaths is crucial. Hands-on learning on the machine under an instructor’s supervision accelerates skill acquisition.
Advanced programming techniques require an additional six to twelve months of intensive practice. Process simulation and path optimization represent the most challenging learning phase. Specialized courses offered by machine manufacturers shorten the learning curve. CAD/CAM programmers experienced in 3D modeling adapt more quickly. Continuous skill development continues throughout the first year on the job.
What is the difference between 3+2 machining and full five-axis machining?
The 3+2 mode involves positioning two rotary axes before starting the cutting process. Then, the machine operates like a standard three-axis milling machine at the set angle. The operator can perform several operations at different orientations without repositioning the workpiece. This method is suitable for simpler geometries requiring angled access.
Continuous five-axis machining allows simultaneous movement of all five axes during cutting. The tool can move along complex freeform surfaces without interruption. The geometric capabilities far exceed those of the 3+2 mode. Hardware and programming requirements are significantly higher. Full control of all five axes enables smoother surface finishes. The hourly machine cost in continuous mode is often about 30% higher than in positioned mode.
What dimensional tolerances can be achieved in multi-axis machining?
Modern multi-axis CNC lathes typically achieve dimensional accuracy from ±0.005 mm to ±0.01 mm. Precision machines made in Japan or Germany maintain tolerances around ±0.003 mm. Dimensional repeatability remains even higher than absolute accuracy. Eliminating multiple re-fixturing removes the main source of cumulative errors.
Achieving the highest precision requires meeting additional conditions. Thermal stability of the production hall and proper machine maintenance are crucial. The quality of cutting tools directly affects tolerances. Regular calibration of measurement systems keeps parameters within standards. Parts with tolerances below ±0.002 mm require an air-conditioned environment. Advanced thermal compensation systems improve dimensional stability during long production runs.
How much does multi-axis technology reduce part production time?
Cycle time reduction reaches from 50% to 70% compared to conventional methods. The greatest savings apply to parts that previously required four or more repositionings. Complex aerospace components traditionally made over several days are completed within one working day. Process automation eliminates waiting for operator availability.
Total order fulfillment time is further shortened by simplifying production setup. No need to design specialized fixtures saves weeks of engineering work. Single programming instead of multiple operations reduces preparation time. Companies report shortening prototype delivery times from three weeks to five working days. Production flexibility allows quick response to urgent customer orders. Downtime between operations virtually disappears when working in a multi-axis system.
Summary
Multi-axis technology in CNC turning fundamentally changes the capabilities of modern mechanical production. Increased dimensional accuracy eliminates problems related to error accumulation from multiple re-fixturing. The ability to complete a part in a single setup shortens order fulfillment time by up to 70%. Economic savings are realized through reduced tool wear, material optimization, and labor cost reduction.
Multiaxis systems enable the machining of advanced geometries that are impossible to achieve with traditional methods. Deep undercuts, complex recesses, and irregular contours are created in a single machining cycle. Improved surface quality often eliminates the need for additional finishing operations. Roughness parameters reach values comparable to precision grinding.
Investing in multiaxis technology brings tangible competitive advantages to manufacturing companies. Shortening order fulfillment times improves customer satisfaction and increases market share. Production flexibility allows quick responses to changing requirements. Companies using advanced CNC systems build a technological advantage over competitors relying on conventional methods.
Sources:
- https://en.wikipedia.org/wiki/Multiaxis_machining
- https://pl.wikipedia.org/wiki/Toczenie
- https://en.wikipedia.org/wiki/Computer_numerical_control
- https://www.sciencedirect.com/science/article/pii/S2666412724000035
- https://yadda.icm.edu.pl/baztech/element/bwmeta1.element.baztech-volume-1427-9126-pomiary_automatyka_robotyka-2008-r__12_nr_2