Comparing 3 Axis, 4 Axis, and 5 Axis Milling
Ego Manufacturing Group’s CNC engineers will help you make the right milling choice for your specific part and application needs, whether it is pure machined parts, or a secondary machining process for castings(investment casting, die casting, sand casting, gravity casting), stamping parts and welded parts. When it comes to choosing 3-, 4-, or 5-axis milling for the components in your production, manufacturing will be the key decider in your choice; factors including cost, turnaround times, and precision.
3 Axis
Evolved from the practice of rotary filling, 3 axis machining is an average manual milling technique cutting parts on three axes; the X, Y, and Z axes. The vertical 3 axis CNC milling machine has come a long way in its capabilities. While many machines have a moving bed, the 3 axis milling centers stand still while the cutter itself operates instead. 3 axis models are multifunctional, accurate machines designed for:
a. Secondary process for stamping, welding, cutting and castings
b. Milling Slots
c. Drilling Holes
d. Cutting Sharp Edges
e. Tool & Die Making
3-axis milling is capable of creating the same products as 4 axis and 5 axis machines, but the 3 axis machines cannot deliver the same level of detail or efficiency as its predecessors. 3 axis can cut individual features during operations, but it cannot match the work of a 5 axis in quality or profitability.
4 Axis
Similar to the 3 Axis CNC vertical milling machine, 4 axis micro-milling machines are vertically operated and built to function in a timely fashion. They are user friendly with manual and computer lead operations. Built for detail work and accuracy, 4 axis is a step away from the high quality, precise engravings, drillings, and millings of a 5 axis machine. Despite its short comings, the 4 axis CNC machine can be used for different purposes, including:
a. Industry
b. Technology Research
c. Teaching
d. Hobby Prototype Building
e. Advertising Design
f. Creating Art
g. Medical Equipment Creation
h. Tool & Die Manufacturing
With the ability to operate on wood, foam, composite board, aluminum alloy, and even PCB, 4 axis is a multi-use CNC tool functioning at a slightly higher competency than the 3 axis.
5 Axis
The best CNC milling machines available today, 5 axis milling is a fast working, precise, micro machining powerhouse. Ego Manufacturing Group specializes in 5 axis machining because of its superior functions compared to the 3 axis and 4 axis CNC Machines. A 21st century marvel, a 5 axis machine is capable of impeccable product and parts creation. This extremely fast milling machine, unlike the 3 axis and 4 axis, has the capabilities to efficiently and impressively produce:
a. Artificial Bones
b. Aerospace Products
c. Titanium Creations – For Both Practical and Artistic Purposes
d. Oil and Gas Machine Parts
e. Car Moulds
f. Medical Technology
g. Architectural Door Frames
h. Military Grade Products
5 axis CNC is capable of cutting the most complex and tedious designs existing in the world. It can operate much faster than 3 axis and 4 axis CNC machines and provide vertical milling with the highest precision and quality available today.
Benefits of 5 Axis Machining
a. Less fixture preparation–Saving time and money.
b. Workparts are not moved through several workstations, they can be completed on the 5 Axis machine alone–Finishing components with greater accuracy.
c. Single setup required for machining complex shapes–Increasing productivity.
d. Ability to achieve outstanding surface finishes–Improving over all part quality.
e. Can use shorter cutting tools–Producing higher cutting speeds and fewer tool vibrations for higher precision.
Expanded Possibilities with 5 Axis Machining
In many cases, a 3 axis CNC machine can do the work of a 5 axis CNC machine – not to say with the exact same precision. The main difference is the setup and fixturing time. Setting up a single job on a 3 axis CNC machine can take 5 hours for one piece, including the rotations needed to complete the fabrication. Setup and fixturing of the same job on a 5 axis CNC machine would take less than 2 hours. Cycle time is also significantly decreased by using a 5 axis machine over a 3 axis machine, reducing it by more than 1/3rd.
And, for repeat jobs, once the initial setup has been completed, the next time the job rolls around it is finished much quicker since the specifications are already programmed into the machine. Less time spent setting up and fixturing machines means better turnaround times, and more opportunities to take on other jobs.
Tight Tolerance Wire EDM
Our 5 Axis Wire EDM Machines offer true 5th axis rotary index wire cuts. We have a specially integrated submersible 5th axis indexer to our super precision Wire EDM machines. Often, people refer to the head tilt option, which is common in most Wire EDMs, as being 5th axis work. Actually, in that context, ours would be considered 6 Axis Wire EDM work.
High Precision, Higher Quality
Our machinists perform ultra-precision 5 Axis Precision Machine work with 5 Micron Tolerance and .0005° angular accuracies.
Problem Parts? Impossible Components? In a Hurry? We are happy to help!
Surface Finish
Ego offers varies of surface finish services, including powder coating, painting, anodizing, plating, laser marking…