Five-axis CNC machines are one of the most advanced options for creating precision parts. These machines can maneuver in ways traditional tools can’t, opening up new possibilities for complex designs. But with all their amazing capabilities, it's easy to get overwhelmed by the different types of 5-axis CNC. 

There are several types of 5-axis CNC machines, and each one offers a unique method of moving the tool and workpiece to achieve complex geometries with high accuracy. These machines are ideal for industries requiring accuracy in parts.

In this article, we'll review various 5-axis CNC machining options, helping you understand their differences. Keep reading to learn how to choose the right one for your needs. 

Types of 5-Axis CNC Machines 

For different 5-axis CNC machines, the main difference lies in how the machine's rotational axes are configured. Two of the most common setups are the trunnion table machine and the swivel head machine. 

We'll also discuss the differences between simultaneous and index 5-axis systems. 

Understanding Trunnion and Swivel Head Configurations 

If you need to handle larger parts and heavy material removal, you may want to choose a trunnion setup. If flexibility and the ability to access tight spaces are more important, a swivel head machine could be the right option. Let's discuss these two types of 5-axis CNC machines: 

Trunnion Table Machine

The trunnion table machine, often called the table-table configuration, is a type of 5-axis CNC machine where both of the rotary axes are integrated into the table. The machine head stays fixed in place while the table rotates the workpiece. This setup is similar to a standard 3 axis CNC machine but with added rotary movements to orient the material.

One of the major advantages of this configuration is its undercut capability. The trunnion design allows the table to tilt at a greater angle than other setups, giving the machine the ability to access harder-to-reach areas. This feature is especially helpful for parts that need complex shapes or cuts. And the machine typically offers a larger work envelope, meaning it can handle larger parts more effectively than some other 5-axis machines.

Because the table does the rotating, the machine can handle heavy-duty operations and metal removal with ease. This setup also tends to be more stable, reducing the risk of misalignment during machining. Plus, it can be paired with powerful spindles that provide more torque at low speeds, making it ideal for demanding tasks that require both strength and precision. 

Swivel Head Machines

In contrast to the trunnion configuration, swivel head machines move the tool head to achieve rotation, keeping the table stationary. These machines come in two main configurations: head-head and head-table.

In a head-head configuration, both rotational movements happen at the tool head. The table remains fixed, and the head swivels to position the tool for precise cuts. This setup allows for more flexibility in positioning and is perfect for smaller parts or tasks that require fine detail. For this reason, it's more suitable for custom CNC machining services. 

On the other hand, the head-table setup features a tilting head paired with a rotating table. This design is more robust and capable of handling heavier materials. Since the table stays stationary, it allows for larger parts to be placed securely on the machine without the risk of tipping or instability. The rotating head and tilting table together make this configuration more versatile for different types of projects, from lightweight tasks to larger, more demanding machining jobs.

Swivel head machines excel in applications where space is tight, or shorter tools are needed to maneuver into smaller areas of a workpiece. They are also capable of processing heavier materials, making them a great choice for industries like aerospace or automotive, where precision and strength are equally important. 

Differences Between Simultaneous and Indexed 5-Axis Systems 

In 5 axis machining, both simultaneous and indexed systems have their place. How do they differ, and which one is right for your project? Let's break it down.

Simultaneous 5-Axis System

Simultaneous 5-axis machining, often called 5-axis simultaneous milling, allows the cutting tool to move along all five axes at once. This means the tool can adjust continuously during the cutting process, enabling it to approach the part from nearly any angle. It’s perfect for creating parts with complex, intricate geometries, such as turbine blades, aerospace components, and medical implants.

The real benefit of simultaneous milling lies in its ability to maintain continuous contact between the cutting tool and the workpiece. As a result, you'll get smoother cuts and more precise shaping, even on multi-faceted parts. In fact, many parts that would normally require multiple setups and repositioning can be machined in fewer steps. 

The method also results in better surface finishes because the tool can continuously adjust its angle that minimizes imperfections.

Indexed 5-Axis System

Indexed 5-axis machining, on the other hand, works a little differently. While it still allows the workpiece to rotate on two additional axes, it doesn’t maintain continuous tool movement during the entire machining process. Instead, the tool cuts one side of the part, then the workpiece is rotated or indexed to the next position. This system is often referred to as 3+2 machining because, like traditional 3-axis CNC machining, the cutting tool only moves in three directions during each setup, with the table rotating between cuts.

Indexed machining can handle more straightforward designs like boxy or prismatic parts that don't require extreme detail. It's also less expensive than simultaneous 5-axis systems. 

Key Differences Between Simultaneous and Indexed Systems

Precision and Complexity: If your design includes multiple angles or intricate curves, simultaneous milling is the way to go. Indexed milling is better suited for parts that don't have extreme detail or require constant tool adjustment.

Efficiency and Cost: Indexed milling setup doesn't need frequent repositioning, so it costs less for certain projects. Simultaneous milling is more expensive as it requires additional machinery for continuous tool movement.

Flexibility: The simultaneous system is incredibly versatile, capable of machining intricate shapes and multi-sided parts in a single setup. Indexed milling, while not as flexible, is still great for parts that need to be machined from multiple sides with simpler geometries. 

Choosing the Right Machine for Your Application 

Choosing the right types of 5-axis CNC machines for your application is a critical decision that can impact both the efficiency and quality of the manufactured parts. Here are some important things to think about before making a choice: 

1. CNC Processing Power

You'll need a CNC machine with enough processing power to handle the simultaneous movements of all five axes. The CNC control system must be capable of calculating and managing all operations, especially during complex machining tasks. 

For example, if you're using a simultaneous 5-axis machine, you'll need a CNC control with high computational ability. Look for a machine with a look-ahead function of at least 1,000 blocks to manage these calculations at high speeds.

2. Spindle Rigidity and Power

The spindle holds the tool in place during machining. It must have enough rigidity and power to handle the forces generated during cutting. 

For demanding tasks, you may need a spindle that delivers between 11 kW and 15 kW of power and a maximum torque of 100 Nm or more. Selecting a more powerful spindle may increase initial costs, but it can pay off in the long run by improving the machine’s performance and longevity.

3. Tool Holding System

To prevent errors and vibrations, it's essential to have a tool holding system that can securely attach the tool to the spindle. Systems like HSK (Hollow Shank Taper) or BBT (Big Plus) can maintain a firm grip on the tool, even during high-speed operations. 

4. Adapting Cutting Feed Rates

Different machining tasks may require different cutting feed rates to achieve optimal results. The ability to adjust the feed rate during the process is crucial for ensuring precision and efficiency. Look for a machine that allows you to adapt the feed rate according to the changing conditions of the material or the cutting process. 

5. Durability and Tolerance

Consider the machine's construction and the materials used in its design. Machines with high-quality construction and calibration systems (electronic systems for optimization) will ensure consistent results over time. Durability is especially important in industries that require tight tolerances, such as aerospace or medical device manufacturing.

Conclusion 

There are different types of 5-axis CNC machines, and selecting the right one depends on your specific needs. Trunnion table and swivel head configurations offer distinct advantages in flexibility, stability, and precision. Whether you opt for simultaneous or indexed systems, consider factors like spindle power, tool holding, and machine durability. 

Looking for precision 5-axis CNC machining parts? Zintilon offers high-quality parts, competitive pricing, and fast lead times. With our cutting-edge technology and expertise, we provide the best CNC machining services. Contact us for a quote or to learn more about our services.