5axis

Five-axis machining refers to computer numerical control processes that use five independent axes of motion. In a typical setup, three linear axes (X, Y, Z) move the tool or the workpiece, while two additional rotary axes provide tilting and rotation. This arrangement allows the cutting tool to approach surfaces from multiple orientations, enabling access to complex geometry and undercuts that are difficult or impossible on traditional three-axis machines.

Configurations vary. The rotary axes are commonly labeled A, B, and C and can provide various combinations of tilt and rotation. Common layouts include a table-tilt axis paired with a rotary axis on the spindle or head, or dual rotary axes on both the table and spindle. Simultaneous five-axis machining uses continuous motion of both rotary axes during cutting for full orientation control.

Applications span aerospace components such as airfoils and turbine blades, medical devices, automotive parts, molds and dies, and sculpted freeform surfaces. Five-axis capability is especially valuable for high-precision surfaces, complex cavities, and parts that require minimal setups.

Programming and control rely on advanced CNC controllers and CAM software. Toolpaths must account for kinematics, collision avoidance, and machine limits, while achieving appropriate surface finish and dimensional accuracy. Rotary axes are driven by servo or direct-drive motors and are sensitive to rigidity, backlash, and calibration.

Advantages include greater access to complex geometries, reduced fixturing and post-processing, shorter tools and cycle times in some cases, and improved tolerances and surface quality. Disadvantages encompass higher cost, increased programming and maintenance demands, and potential for longer setup and optimization times if not properly managed.

Five-axis technology emerged in the late 20th century and has become standard in high-end manufacturing, with various machine configurations optimized for specific applications.