The differences between 3 axis milling, 4 axis milling, and 5 axis milling can be confusing at first. We’ve created this guide to help you understand how each one works and which one will best suit your needs.
What is Milling?
Starting with the basics, milling is a subtractive manufacturing process that uses rotating cutters to remove material from a workpiece. In other words, it’s how you create objects by shaping them out of other materials. Milling machines can be divided into three types: vertical milling machines, horizontal milling machines, and lathes.
These days, most machining operations combine several types of machines in order to achieve higher accuracy and precision. Milling only refers to these methods of cutting with machine tools. Although, there are more generic machining that include drilling, grinding and broaching, as well as, turning. So what does all of that mean? Let’s take a look at each one individually!
Lathes
One of those types, lathes is a 3-axis CNC machine. 3-axis -CNC lathes turn a block of material around its main spindle, which runs vertically along its Z axis. A CNC lathe typically uses only two other axis. This includes one that runs left to right and one that runs in and out along a plane perpendicular to those of X and Y. These are both attached to swivel mechanisms called toolposts.
A variety of functions use the third axis that include cutting threads, drilling holes, and adding or removing material from parts on their way through production. Because it lacks an independent rotational ability on its own, a 3-axis CNC lathe can’t create objects with details smaller than one inch (25 mm) in diameter. Although this limits the machine, mechanics rarely need such small details since most manufacturers’ target customer bases.
Horizontal Milling
CNC Horizontal Mill Machines are excellent for many industries such as precision machining, aerospace, nuclear and more! They have a complete X/Y axis with a rotary table as well as an X/Z axis. The rotary table helps you achieve perfect milling operations every time. How much load your job requires or what industry you are in will determine the need for machine power to correctly and efficiently complete the project.
If you would like assistance with a CNC service, please contact us today. One of our expert engineers will answer any questions that you may have about your next project and can assist in putting together a custom quote for you.
Vertical Milling
CNC vertical milling machines are valuable workhorses in a shop’s arsenal of metalworking machinery. They are capable of generating precision and power that far surpasses what a manual machine can achieve. Yet they are at a cost point that is much more accessible to most shops than CNC lathes or horizontal machining centers.
These machines have been around for decades and have become increasingly important over time as more shops automate their production processes. Here we will explore some of the differences between 3-axis, 4-axis, and 5-axis vertical milling machines.
The Difference Between Three-Axis Milling and Four-Axis Milling
In a three-axis milling machine, there are three axes of movement—the X, Y and Z axis. X axis means up/down, Y axis means left/right, and Z axis means forward, backward. The fourth axis allows for additional movement on all three axes at once, which makes it possible to do 3D milling on a part.
This is useful when drilling multiple holes along an edge that don’t perfectly align with each other; after one hole is drilled, more can be added along that edge without having to reposition the workpiece.
What is 3D Milling?
Lets take a step back to 3D milling. 3D milling is a type of CNC machining process that involves using computer software to send signals to a CNC milling machine that allows the part to rotate and move on 3 axes (X, Y, Z). machinists most commonly use 3D milling for rough cutting shapes out of raw material or carving fine details into a surface.
The machine uses a rotary tool bit or end mill as the cutting tool, which spins at high speeds (20,000 rpm) while it moves along one of its 3 linear axes. Depending on what part you’re working with, 3D milling can take place in either metal or plastic.
So why would someone want to go beyond basic 3D milling? There are actually quite a few reasons why someone might want to consider moving onto 4 axis and 5 axis machining: A big step up from basic 3D milling, 5 axis machines allow you to change both an object’s length and width during production—which essentially gives you freedom when it comes time to finish your parts.
The Difference Between 4 Axis & 5 Axis Milling
5 Axis machines are similar to CNC milling machines and have a spindle along with four axes, but they also have an additional rotary axis that allows parts to be rotated freely in addition to moving them side to side, up and down or in any direction around a central point.
The additional rotating axis allows more room for creativity as it enables parts to be engraved, cut into or milled on all sides of a part instead of just one side like when using a CNC machine’s four axes. Although both types of machines can perform similar functions, 3 axis and 4 axis mills do so differently.
3 Axis mills use three moveable arms that move in front of each other along separate X, Y and Z planes. They provide movement while 4-axis mills use all three arms. This includes a fourth arm which moves in an A plane. This allows easy rotation around X/Y/Z axis. Because these two different types work differently there are also some differences between how they handle materials.
What are the Benefits of Using 5 Axis Milling?
Unlike 3 and 4 axis milling machines, a 5 axis machine allows for more versatility in designs. With five axes of movement, you are able to move around any corner or surface with ease. This can create products that would be impossible on a traditional 3 or 4 axis machine. Plus, 3 and 4 axis machines only have two cutting tools at their disposal. There is one horizontal spindle tool that is always located above another vertical tool on a swivel.
So if you want to carve out something like an apple with your CNC router or mill, your horizontal spindle tool would have to do all of the work. This includes remaining perfectly parallel along its X, Y & Z axis’s while also maintaining contact with your material at all times.
On a 5 axis machine, however, there are 3 tools in total. These include one vertical tool and two horizontal spindles. This means much more intricate cuts can be made with greater precision due to being able to utilize both right angles on a single piece of material.
What is a 5 axis CNC Machining Center?
A five axes machine has a moveable head that can rotate on five different axes. As such, it can make a range of rotary and linear movements to create complex shapes in metal, plastic and other materials in applications such as aircraft parts, electronic devices and consumer goods. Not only does a CNC 5 axes machining center provide greater flexibility for making different shaped objects, but it also allows for higher speeds due to its precision capabilities.
The more moving axes means that these machines tend to be larger and heavier than their 3-axis counterparts. Most 5 axis machines are considered horizontal boring mills because they rely primarily on a rotary motion rather than a straight line path during machining. There are examples of vertical, 4 axis milling centers in automotive assembly lines.
5 Axis Milling Applications
A machinist can use 5 axis milling to make any complex contour. It is especially useful in mold-making applications, such as tooling for injection molding and die casting. There are complex 3D shapes that need to be replicated. They can also use five axis milling for multiple parts of an assembly at once on a single material stock.
By using a multi-axis system, they can easily make complex castings and deep pockets. They allow you to move each of your cutting tools in space. There’s no longer a limit on how far you can reach into or over your work piece without destroying your spindle bearings. Because five axis machines have become more mainstream, many companies who regularly perform large amounts of 3D milling use them. This includes toolmakers, aerospace companies, medical research facilities and universities are just some examples.
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