Understand the Main Difference between 3-Axis, 4-Axis, and 5-Axis Milling

09 June 2022

For decades, manufacturers have opted for manual machining as part of their operations. By physically controlling the movement and behaviour of the tools, workers can see first-hand the progress of their works. Doing this, however, poses safety risks. Manual machining is also prone to errors and waste.

To ensure the safety of workers and minimise the chances of errors, manufacturers swiftly adopt computer numerical control (CNC) machining. CNC machining, as its name implies, utilises a computer in handling the operations of the tools. Through computer-aided designs, the software from a computer can send a set of commands to the tools, granting industries a production that is more accurate, more consistent, and safer. One of the tools that can benefit from CNC machining is milling machines.

Milling machines utilise rotary tools to cut materials away, producing high-quality parts. To date, these machines can utilise either 3, 4, or 5 axes.

3-Axis Milling

For parts that only require simple modifications, they can already be processed with a 3-axis milling machine. This type of milling machine can move the cutting tool vertically or on Z-axis. The tool, which is attached to a spindle, can also move in an X and Y direction at thousands of RPM, making the whole machine effective in processing sturdy materials accurately and easily. The workpiece, alternatively, does not move during the milling process as it is fully fixed in a single position.

The 3-axis milling machine can be utilised for machining 2D and 2.5D geometry. It can also machine all six sides of a workpiece, as long as a new fixturing set-up is present for each side. Complex and practical shapes can likewise be processed by this machine, making it effective in manufacturing planar milled profiles, drillings, and threaded holes.

4-Axis Milling

The 4-axis milling machine, alternatively, can also move similarly to the 3-axis milling machine with the addition of an A-axis movement. The A-axis movement is intended for the rotation of the workpiece. The workpiece in this machine is mounted on the X-axis, which rotates alongside the fixture on the A-axis. Through a single fixture setup, the 4-axis milling machine can process four sides of the workpiece.

Since a 4-axis milling machine adds the ability to move the workpiece, it can process parts that are theoretically possible on a 3-axis machine more efficiently. A 3-axis machine may require two unique but expensive fixtures in processing a workpiece. But with a 4-axis milling machine, the same workpiece can already be processed with only one fixture. By utilising this type of milling machine, manufacturers can expect more savings. Fixture changeovers and human errors are also eliminated with this machine.

5-Axis Milling

Ultimately, the 5-axis milling machine includes a rotation in the A- and C-axis or a rotation in the B- and C-axis, making it the most comprehensive milling machine that manufacturers can utilise today. This milling machine can be very useful in processing complex 3D parts like medical devices, implants, impellers, and aerospace parts. Flexibility, after all, is enhanced with this type of milling machine.

To learn more about milling machines, you can contact us at Kinetic Engineering.

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