1. Single Setup: Three-axis machines require multiple setups, which can lead to incorrect alignment, higher costs, and other errors. Using CNC 5-axis machining, we can machine complex shapes with a single setup, increasing efficiency, saving time, reducing costs and preventing operator error.
2. Shorter cutting tools: CNC five-axis machining allows us to use shorter cutting tools because we can lower the head and orient the tool properly. This helps achieve higher cutting speeds without putting too much pressure on the cutter. Shorter cutting tools also reduce tool vibration, which can cause cavities and cores. Since the five-axis machine has less vibration, we see a better surface finish.
3. Complex parts: This process allows us to machine complex parts that would otherwise require casting. If we have low volume production or prototyping, parts can be machined in weeks instead of months for casting.
4. Hole drilling: CNC five-axis machining provides the ability to drill a series of holes with various compound angles in time. This saves a lot of time. If we were using a 3-axis machine, we would need to use different settings for each hole.
5. Collision avoidance: The ability to tilt the table or cutting tool to prevent collision with the tool holder.
6. Extend tool life: We can maintain constant chip load and optimal cutting position, thus extending tool cycle time and life.