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6 Axis CNC Machining

6-Axis Machining

The advancements in technology have brought many changes to manufacturing in the last few decades. CNC machining has experienced this massive growth with Industry 4.0 and IIoT alongside the introduction of multi-functional and multi-axis technology in smaller machines. 6-axis machining has enabled faster production enabled by collision detection, simulation software, and higher-speed tools. The demand for 6-axis machining has been prevalent in automotive, aerospace, and metal fabrication for many years. These changes in technology are making it affordable for smaller machine shops, as well.

 

What is a 6-Axis Machine?

CNC machining started with the cutting tool moving along 3 axes – front to back, side to side, and up and down. These are the X, Y, and Z axes, important industry standards for accurate G-code and software programming. Fabrication of complex parts can be completed on a 3-axis machine, but this requires re-setting the workpiece for each cutting approach and angle. The addition of the A-axis introduced the rotation of the workpiece on the X-axis to create 4-axis machining. This allowed tool access from new angles to prevent resetting the workpiece resulting in time and error savings. 5-axis machining introduced the B-axis, rotating the spindle on the Y-axis to further speed up production and create more intricate shapes. 6-axis machining now rotates the Z-axis to re-position the cutting tool itself, often used in conjunction with a multi-tool holder. Complete tooling of a complex part can be produced on one machine in a single operation with the addition of the C-axis in 6-axis machining.

 

Advantages

Some studies indicate as much as a 75% increase in productivity moving to a 6-axis machine. When you consider the jump in productivity from a 3-axis to a 4, this is astounding. The increased capability for lean manufacturing produces higher quality products in less time.

The complex geometries are the biggest advantage of 6-axis technology. Manufacturing many parts at high speeds can be accomplished on lower multi-axis machines, but adding complexities is where the 6-axis machine shows its performance. The incredible control for rounded shapes or curves and minute control for shaving and trimming simply can’t be accomplished with other machines.

Machining of softer materials like aluminum, wood, and thin steel is more successful with 6-axis machining as there is less chance of deforming and the associated problems from heat from friction.

Machining with 6 axes also provides a higher metal removal rate, minimal radial and axial run, deep angle accuracy, reduced waste, and better surface finish. When all axes can freely rotate, not only can multiple sides of the piece be tooled, but curves and helixes can also be introduced easily. Extremely large parts, like aircraft blades and missiles, can be tooled on a 6-axis machine, but so can the extremely small parts in the micro-machining industry.

 

Precautions

Multiple angles and high-speed increase the chance of unwanted part contact. 6-axis machines must operate with sensor technology introduced with IIoT to constantly monitor the cutting tool. This collision detection will stop processing before damage occurs to the cutting tool or the larger parts due to a high-speed contact.

The benefit of completing an entire project on one machine can contribute to a secondary problem. In CNC machining, an idle machine is the largest inefficiency for any shop. But also be aware that one machine providing complete production from start to finish makes the machine unavailable for other operations. Purchasing a 6-axis machine should be limited to manufacturers producing high volume, complex, expensive parts. When a 4- or 5-axis machine can be used for various functions, production runs can be managed to balance machine use as needed to satisfy a variety of production runs at one time. A breakdown, similarly, also means a complete cease of production. Repair and maintenance must be activated quickly and efficiently.

The cost for a 5-axis machine can range from a low end of $3000 up to $500,000 for an industrial machine. A 6-axis machine is a much higher investment. The application must be warranted for the initial investment, as well as budgeting for training and a higher level of maintenance. Overall operating costs are higher but pay great dividends when part production warrants the speed, accuracy, and complexity 6-axis machining delivers.

 

Adding 6-axis machining is a worthy investment when complex parts manufacturing can balance the investment. The rapidly advancing technology needs to keep up with new CNC machine designs and new machines need to continue to develop with the technology. Where collision-preventing software was considered a luxury for advanced automation, it is a necessity with 6-axis machining. CNC machining is a constantly emerging market that will continue to offer machines, software, and technology that will compensate for the job skills gap the industry is currently facing. If you can dream it, someone can build it. Ask about our services to meet your needs at Rapid Enterprises.




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