In industries such as automotive and aerospace, the need to manufacture highly accurate parts is increasing day by day. In order to meet these needs, 3+2 axis CNC machining provides high quality and efficient production of parts. It achieves these benefits without added complexity compared to full 5-axis machining.
In this blog post we will cover what 3+2 axis CNC machining is and its fundamentals. We will also see benefits and applications of this important machining method.
Understanding CNC Machining Axes
CNC machines are classified according to their rotary and linear motion. There are three basic types of linear motion which include X (left to right), Y (front to back) and Z (up and down). To position tools at different angles, modern CNC systems also include rotary axes (A, B and C). A axis rotates around X, B axis around Y and C axis around Z.
Machines with only three axes (X, Y, and Z) are usually used to make simple parts on a single plane. The addition of a fourth axis (the A-axis) permits multi‐sided machining by rotating the workpiece. Meanwhile five-axis machines also include B and C axes which enable simultaneous rotation and linear movement of tool. This capability allows complex shapes to be machined with less setup.
Also See: What is 5 axis CNC Machining
What is 3+2 Axis CNC Machining
Commonly known as positional 5-axis machining, 3+2 axis CNC machining combines the precision of traditional 3 axis milling with two additional rotary axes (A and B). In this method workpiece is positioned and locked at specific angles rather than rotating continuously. This arrangement permits multi‐sided machining through fixed positioning.
How 3+2 Axis Machining Works
3+2 axis machining serves as an intermediate solution between basic 3 axis milling and simultaneous 5-axis machining. Below are some details about the practical workings of this process.
1. Machine Configuration & Setup
The workpiece is first fixed on a tilt rotary trunnion or rotary table. This equipment provides two additional rotational axes (usually A and B). These rotary axes do not move continuously, unlike 5 axis machines. Instead they are locked at fixed angles such as 30°, 45° or 90° by hydraulic clamps or servo motors.
The spindle then positions the cutting tool perpendicular to the surface to be machined. This arrangement permits the use of smaller and stiffer tools which results in less tool vibration and deflection.
2. Machining Process
After fixing the axes CNC machine performs a 3 axis milling operation along the X, Y and Z axes. Throughout this cutting process, angular orientation remains fixed.
In order to machine multiple sides of a part, rotary axes reposition the workpiece between machining operations. This repositioning eliminates the need for manual re-machining. Using this index‐and‐cut mechanism, complicated features such as deep cavities or undercuts can be machined in a single setup.
Advantages of 3+2 Axis CNC Machining
Better Tool Accessibility
3+2 axis machining positions the cutting tool at specific angles by using two rotational axes. Such positioning allows you to use stronger & smaller tools to reach difficult areas such as steep walls and deep cavities. Since smaller tools experience less deflection, dimensional accuracy is improved when machining complicated geometries.
Cost Effectiveness
3+2 machining needs simpler programming and involves lower initial costs as compared to simultaneous 5-axis machining. Furthermore this method decreases material waste and tool wear which further reduces overall production costs.
Improved Accuracy and Surface Finish
In 3+2 axis machining there is reduced chatter and vibration because of fixed positioning of cutting tools at optimal position. Consequently this leads to tighter dimensional tolerances and smoother surface finishes in your machined parts.
Reduced Setup Times and Increased Efficiency
In 3+2 machining you can process multiple surfaces without repeatedly repositioning the workpiece. Such processing reduces your cycle times & improves production efficiency as well.
Applications of 3+2 Axis Machining
Automotive Industry
Automotive sectors often use 3+2 axis machining to produce complicated components such as valve bodies, transmission housings & engine parts. Since this technology reduces the number of setups and increases manufacturing efficiency, it is very useful for high performance automotive applications.
Medical Industry
In the medical sector 3+2 axis machining is essential for manufacturing surgical instruments and implants such as knee and hip replacements. The precision obtained through this process ensures flawless designs and biocompatibility which meet the strict standards of medical industry.
Aerospace Industry
3+2 axis machining is often used in the aerospace sector to manufacture structural components, turbine blades & engine parts. This technology is well suited for machining undercuts, compound angles and steep walls. As a result it provide better surface finish and tight tolerances which are needed for strict safety standards and aerodynamic performance.
Die and Mold Making
3+2 axis machining is very beneficial when producing dies and molds with deep cavities and complicated shapes. The use of small tools reduces the risk of deflection which increases reliability and accuracy in complicated dies and molds.
Comparing 3+2 Axis Machining to Simultaneous 5-Axis Machining
Pros and Cons of Each Method
Using simultaneous 5-axis machining you get better accuracy, less setup work and can make complicated parts in a single setup. However for this approach a larger initial investment is needed. You also need operators with specialized knowledge as well as advanced programming expertise.
On the other hand 3+2 axis machining is more affordable and easier to program. The disadvantage is that when working on complicated or highly detailed parts you may need additional setups.
How the Operations Differ
In simultaneous 5-axis machining all five axes move continuously throughout the machining process. On the other hand, in 3+2 axis machining, two rotational axes are first used to orient the workpiece at specific fixed angles. The machine then performs standard 3 axis cutting operations without further rotation.
Decision Making Factor
Your need to consider complexity of parts, available budget and specific production requirements. Simultaneous 5-axis machining is well suited for industries like medical or aerospace where extreme precision is needed.
On the other hand 3+2 axis machining works well for simpler parts or when keeping costs down is important.
| Feature | Simultaneous 5-Axis Machining | 3+2 Axis Machining |
|---|---|---|
| Complexity | Complex programming & setup | Simpler programming |
| Cost | HigherHigher | Lower |
| Operation | Continuous motion of all 5 axes | Fixed tool angles with 3 axis cutting |
| PrecisionPrecision | Well suited for highly complicated shapes | Good for less intricate geometries |
| Setup Time | Single setup for most parts | May need multiple setups |
| Tooling | Shorter tools with dynamic angle adjustments | Shorter, rigid tools |
Implementing 3+2 Axis Machining in Manufacturing
You must consider your software choices, equipment and workforce training to successfully adopt 3+2 axis machining. Below are some important guidelines to get started.
Programming and Software Considerations
Consider investing in advanced CAM software like CAM Assist or Autodesk Fusion 360. Through automating collision avoidance, generating precise toolpaths and speeding up the programming process, these programs simplify your programming tasks. With an efficient CAD software, you can greatly simplify your workflow.
Also See: What is CAM (Computer Aided Manufacturing)
Machine Tool Requirements
You will need a 5 axis CNC machine which includes two rotational axes A and B so that it can accurately tilt and hold your workpiece. Give preference to machines that are known for their accuracy and rigidity. Components like ball screws and linear guides are particularly important.
Also See: 15 Best CNC Machining Manufacturers In The World
Operator Training and Skills
Your operators must be proficient in tool setup procedures, CNC programming and equipment maintenance. To enhance their understanding of multi axis machining processes and CAM software usage, you will need to set up training programs for them.
Challenges and Limitations of 3+2 Axis Machining
Machine Limitations
3+2 axis machining systems are unable to perform continuous motion, unlike full 5-axis machining. This limitation reduces flexibility during complex part production. If your part has angled features or deep pockets you have to reposition the workpiece several times. Due to such repositioning setup times increase which negatively impact overall efficiency.
Programming Difficulty
An advanced CAM software is needed to program 3+2 axis machines so that it can efficiently handle multiple tilted work plans. It is not as complex as simultaneous 5 axis machining, but careful planning is still necessary. Without proper planning toolpaths can overlap. Such overlapping reduces surface quality and results in longer machining times.
Maintenance and Calibration
Your 3+2 machining equipment includes additional rotary axes which need accurate calibration and regular maintenance. In order to avoid misalignment in tool or workpiece positioning, accurate calibration is very necessary. Misalignments can cause dimensional inaccuracies which ultimately affect the quality of your finished product.
To Sum Up
In short 3+2 axis CNC machining provides an economical and flexible way to manufacture complicated components with improved efficiency and precision. By allowing less setups and shorter tools, it simplifies production processes.
If you need any kind of CNC machining services including 3-axis, 4-axis or 5-axis then Richconn is your best choice. You can contact us anytime.
Related Questions
Is programming for 3+2 axis machining more complex than for 3 axis machining?
Programming for 3+2 axis machining is a bit more challenging than for 3 axes machining but it is less complex than simultaneous 5 axis machining.
Can existing 3-axis CNC machines be upgraded to perform 3+2 axis machining?
Yes you can upgrade a 3 axis CNC machine to perform 3+2 axis machining by adding tilt rotary trunnions or rotary tables.
Can 3+2 axis machining be used for both finishing & roughing operations?
Yes 3+2 axis machining can be effectively used for both finishing & roughing operations.
Is it possible to integrate 3+2 axis machining with automation systems?
Yes it can be integrated. Such integration improves accuracy, simplifies setup and increases productivity in automated manufacturing workflows.
Can 3+2 axis machining reduce the need for EDM operations?
Yes 3+2 axis machining has reduced the need for EDM operations in many cases because it allows you to directly machine deep cavities, steep walls & undercuts.
