In the realm of modern manufacturing, complexity is no longer a challenge or constraint, but a strategic advantage to manufacturers. In industries, like aerospace and medical devices, companies are constantly looking for ways to design and manufacture at new capabilities and performance levels. Central to that is complex machining, a collection of precision machining methods and techniques that allow manufacturers to produce geometrically complex parts with demanding tolerances.
One of the technologies that is redefining engineering and machining capabilities is 5 axis machining. But what makes it different from, say, a CNC machine or machining center? And most importantly, in what real-world examples does it work? There is a lot to unpack here!
Let's get started!
1. What is a Complex Machining?
Complex machining (or simply stated complex machine) involves the manufacturing of geometrically complex components that feature things like multi-dimensional geometry, undercuts, compound angles, and challenging tolerances that often can veer far from standardized methods. The key elements of complex machining are often
Tighter tolerances (often to less than 0.001")
Multi-angular and axis movement
Simultaneous part and tool coordination
Higher integrity to material properties
2. What industries use Complex Machining?
Aerospace- Turbine blades, Structural components
Medical- Orthopedic implants, and surgical tools
Defense- Components for arms. Targeting systems
Automotive- Engine housings, custom manifolds
Robotics & Automation- Custom end-effectors, gear components
3. What is the difference between a CNC machine and a machining center?
This is an often-asked question, and the difference is subtle but important:
CNC (Computer Numerical Control)
CNC describes the process of automating machine tools via computer programming. Machine tools follow coded instructions to operate the machine in functions such as drilling, turning, and milling.
Examples:
CNC lathe
CNC router
CNC mill
Machining Center
A machining center is a more advanced CNC machine, as it can combine the machining processes (milling, drilling, tapping, boring, etc.) all in one set-up. A machining center will typically have an automatic tool changer, and sometimes even support simultaneous multi-axis machining.
Key Difference: All machining centers are CNC, but not all CNC machines, are a machining center.
Think of it this way, CNC is the language and a machining center is the multi-lingual genius that speaks many machining languages at once.
5 Axis Machining, A New Level of Capability
The “hub” of complex machining used today is in the 5 axis machining technology. 5 axis machines are different that a traditional 3 axis machine. 3 axis only reference X, Y, and Z, while 5 axis include an additional rotating axis, either A & B or A & C.
4. Why 5 Axis:
Less setups: Less setups results in more accuracy and shorter production times.
Better surface finish: Tool has the proper cutting angle for the material being machined.
Machining of complex geometries: Can reach difficult to access surfaces, while it’s still in the machine.
Longer Tool Life: Optimal angle reduces stress on tooling.
Common Applications for 5 Axis Machining
engine turbine casings
Complexly curved surgical implants
Optical components with undercuts
High-performance automotive components
Discover how our dedicated 5 axis machining services reduce lead times and increase efficiency.
The Types of Machined Components
Machined components can be found in a wide variety of places in our day-to-day interaction with technology and necessary infrastructure:
Custom aluminum heat sinks (electronics)
Stainless steel surgical instrumentation (medical)
Titanium aerospace brackets
Hardened steel dies (manufacturing)
Engine valve bodies (automotive)
Optical lens mounts (defense)
These types of components can often require ultra-refined geometry and surface finish, and therefore use of 5 axes machining should be the instinctive solution.
Three Main Types of Machining Technologies
Machining can be discussed broadly, and most common technologies can be grouped into one of three machines:
1 . Milling
Similar to a hand-held drill, the concept of milling removes material from a work piece with rotary cutters with an axis of feed to minimize the amount of motion across extrinsic planes.
Milling is excellent for producing flat surfaces, slots, and contours whether simply using rotary cutters or enhancing machines with multi-axis capabilities for complex surface geometry.
2 . Turning
A turning machine works by rotating the material while the cutting tool remains stationary and the object then comes from the table side and shafting actions.
Turning is typically seen when producing cylindrical parts such as shafts or pulleys.
3 . Drilling
With drilling, the machining axially creates only round holes.
Drilling allows for drilling and tapping, drilling and boring larger holes, or conventional drilling and threading of components.
A more advanced, hybrid machine processes multiple capabilities to combine these machining activities into one interactive machine process threaded on one platform.
5. How Falcon CNC Precision Machining Monitors Complex Machining
Falcon CNC Precision Machining can uphold the complex machining technologies with extremely precise tolerances using advanced machining equipment including high-end 5 Axis machining centers. Our machining services supports critical industries and work with components with strict mission specifications and traceability standards.
Major Benefits:
In-house engineering support
ISO approved process
Material traceability and CMM inspection
Production support from low to high volume
At Falcon CNC, we believe that great designs deserve great execution. If you're working on a challenging project that demands precision, reach out to us for a consultation. Let's turn complexity into capability.
Questions about 5 Axis and Complex Machining
What is the advantage of 5 axis machining comparison to 3 axis machine processes?
A 5 Axis machining offers an advantage that eliminates some of the need to do multiple setups on simple 3 axis machining processes to establish and assemble an accurate part.
Can a 5 axis machining be used for prototyping?
Definitely; a 5 axis machining is no different than being a splitter for holding an established part geometry, it can be as useful for prototyping as it would for full-scale using complex machining processes.
What materials can be used in a 5-axis machining?
There are many materials suited for 5-axis machining including aluminum, titanium, stainless steel, plastics and exotic metals used for aerospace and medical channels as well.
Is a 5 axis machining more expensive?
Generally, it may take more machine time; however, the price of working on a 5 axis machining is less, because we are going to do less setups, there is no wasted machining time, and it is faster to cycle compared to 3 axis..
