Five-Axis CNC Machining Centers | Modern Machine Shop

Cumberland Additive’s CNC programmer in Pennsylvania spends most of his time writing programs for machine tools in Texas.

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community. server bracket

Small details and features can have an outsized impact on large parts, such as Barbco’s collapsible utility drill head.

Recognizing the demand for automation solutions in grinding and finishing applications, this abrasives manufacturer is providing free consulting services to help shops develop automated processes.

At its 2024 Music Motion Meeting, Studer AG showed off its entry-level line of grinding machines, as well as its newest universal loading system.

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

Intech Athens’ inventory management system, which includes vertical lift modules from Kardex Remstar and tool management software from ZOLLER, has saved the company time, space and money.

Adopting PCD tooling has extended FT Precision’s tool life from days to months — and the test drill is still going strong.

Shops need to look at their people, processes and technology to get the most of out their automation systems.

Controlling variability in a closed-loop manufacturing process requires inspection data collected before, during and immediately after machining — and a means to act on that data in real time. Here’s one system that accomplishes this.

Wolfram Manufacturing showcased its new facility, which houses its machine shop along with space for its work as a provider of its own machine monitoring software and as an integrator for Caron Engineering.

Global manufacturer Fictiv is rapidly expanding its use of data and artificial intelligence to help manufacturers wade through process variables and production strategies. With the release of a new AI platform for material selection, Fictive CEO Dave Evans talks about how the company is leveraging data to unlock creative problem solving for manufacturers.

Hexagon has rearranged its software portfolio into five process-based suites, which include software for every step in the workflow as well as a new program that connects everything, increasing automation and collaboration.

Zeiss Quality Innovation Days brings together quality and metrology experts from all over the world to take part in industry-specific sessions.

Fixed-body mechanical plug gages provide fast, high-performance measurement for tight-tolerance holes.

Thanks to ballbar testing with a Renishaw QC20-W, the Autodesk Technology Centers now have more confidence in their machine tools.

Tool-toolholder-spindle-machine combinations each have a unique vibration response. We can measure the response by tap testing, but we can also model it.

Measuring surface finish at the point of manufacture is often done by the same machinist who is manufacturing the part. They need tools that meet test requirements and are easy to use.

Robotic applications are expanding thanks to rubber and silicone-based systems that can handle fragile materials or parts in varying sizes and shapes.

Shops need to look at their people, processes and technology to get the most of out their automation systems.

Recognizing the demand for automation solutions in grinding and finishing applications, this abrasives manufacturer is providing free consulting services to help shops develop automated processes.

At its 2024 Music Motion Meeting, Studer AG showed off its entry-level line of grinding machines, as well as its newest universal loading system.

Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.

The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.

Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

The advance toward increasingly automated machining can be seen in the ways tooling, workholding, gaging and integration all support unattended production. This is the area of innovation I found most compelling at the recent International Manufacturing Technology Show.

Manufacturing has a multi-talented bunch of people, but who knew so many were adept in the facial hair industry? Check out the best of the beards at IMTS!

This year’s show celebrates 10 years of co-location between IMTS and Hannover Messe.

Brent Donaldson of Modern Machine Shop sits down with Supertec's Don Staggenborg to discuss what the IMTS veterans brought to this year's show.

Meet NASA mission system engineer Mike Menzel and learn more about the James Webb Space Telescope at Mitsui Seiki USA’s booth (338700) in the South Hall from 11:00 a.m. to 11:45 a.m. on Thursday, September 15.

Understanding all the things that contribute to a machine’s full potential accuracy will inform what to prioritize when fine-tuning the machine.

Fixed-body mechanical plug gages provide fast, high-performance measurement for tight-tolerance holes.

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

Verifying parts is essential to documenting quality, and there are a few best practices that can make the quality control process more efficient.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

Explore Tech-Max, a CNC machine shop that specializes in precision machining large and complex parts ranging from 10 in. to over 10 ft.

Jrlon, Inc. is recognized as a dependable source and leading supplier of plastic and specialty metal products. They are one of the premier PTFE processors in the United States. Jrlon's expertise also covers a wide range of other performance plastic materials and alloy steels for custom molding, machining, gear manufacturing, technical industrial coatings, welding, and sheet metal fabrication. Driven by innovative designers and engineers, Jrlon manufactures unique products vital to a wide variety of industries.

In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.

So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?

The Top Shops 2024 survey for the metalworking market is now live, alongside a new homepage collecting the stories of past Honorees.

Doubling sales requires more than just robots. Pro Products’ staff works in tandem with robots, performing inspection and other value-added activities.

From cobots to machine monitoring, this Top Shop honoree shows that machining technology is about more than the machine tool.

Verifying parts is essential to documenting quality, and there are a few best practices that can make the quality control process more efficient.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

Explore Tech-Max, a CNC machine shop that specializes in precision machining large and complex parts ranging from 10 in. to over 10 ft.

The VPick and VPack robotic palletizing and depalletizing solutions use AI vision systems to enhance warehouse efficiency and reliability.

The 1,700-square-meter expansion to the company’s Stans, Austria facility will enable more efficient machining.

The company’s reversible hard jaws are designed to decrease the time and cost of tool setups.

CNC Pros offers a broad range of CNC machine tools in the Southwest region on the U.S.

Russ Reinhart is the company’s new U.S. national sales manager. In addition, John Kusinko has been appointed as the new regional sales representative in New York, New Jersey, Delaware and Eastern Pennsylvania; and Luis Mejia is the new regional sales representative in Mexico.

Prepare for a transformative journey into the future of your manufacturing. Join ECI Solutions for a dynamic panel discussion featuring change management and manufacturing ERP experts. This webinar will equip you with the essential tools and tactics to navigate the human side of change and ensure a smooth, high-impact rollout of your new ERP system. The presenters will cover their expert insights on ERP implementation, some pitfalls during the implementation process and how to manage them, and recommendations on building a culture of change. Don’t miss this opportunity to unlock the full potential of your ERP investment and propel your manufacturing business forward. Register now for a transformative discussion on change management for manufacturers. Agenda: Gain perspectives from leading change management professionals on strategies tailored to the unique challenges faced by manufacturers during ERP implementation Navigate the common roadblocks associated with change and discover practical solutions to overcome resistance, boost buy-in and user adoption, and maximize the ROI of your ERP as soon as it is in your business Learn how to foster a culture of openness, communication and collaboration within your organization, laying the foundation for a successful ERP transition Walk away with a clear roadmap for change management excellence in your manufacturing operations

Adding robotic automation to machine tool processes can bring a level of apprehension and confusion on how, when and where to begin. Kuka offers a wide range of automation technology and industrial partnerships to efficiently and effectively bring a project from conception to completion. Considering automation early on in your machine tool buying process can not only save you money and time but it can also ensure that your machine will be efficient when it arrives at your shop. Agenda: Save time and money by automating before you get your machine tool Simplify the process: simple PLC programming, mobile robots, articulated robots and planning simulation Finding the right automation integration partner What to expect out of your automation supplier and the questions to ask Example applications and use cases

In today's rapidly evolving manufacturing landscape, job shops face unique challenges stemming from a severe labor shortage and the growing demand for faster job setup times. This presentation delves into the crucial importance of automation for job shops and highlights ProCobots as a provider of high-mix, low-volume automation solutions. The discussion begins by addressing the pressing issue of labor shortage, which has compelled job shops to seek efficient and cost-effective alternatives. One of the key solutions lies in the extremely fast job setup time offered by automation systems, which streamline processes and reduce reliance on manual labor. The benefits of collaborative robots (cobots) over traditional industrial robots are also highlighted, emphasizing their versatility, safety, and ease of integration into existing workflows. This presentation showcases ProCobots as a provider of effective high-mix, low-volume automation, pointing to how it can cater to the diverse needs of job shops that handle a wide range of parts and projects. Throughout the presentation, attendees are taken through the step-by-step process of automating a part for a Hurco CNC mill using ProCobots' automation software. From initial planning to seamless integration with the Hurco control, participants gain valuable insights into how automation can revolutionize job shops and drive efficiency, productivity, and profitability. By showcasing real-world examples and practical applications, this presentation aims to inspire job shop owners and operators to embrace automation as a strategic imperative for staying competitive in today's dynamic manufacturing environment. Agenda: Why automation? Collaborative robots vs. industrial robots Why ProCobots: system components and the Hurco Automation Job Manager

This two-part webinar series will explore various levels of AI automation available in today’s manufacturing software. HCL CAMWorks will explore technologies in CAD and CAM software – along with presentations of workflows that save time during both programming and machining processes. This series will focus on ways to improve delivery times by speeding up your part programming and decreasing part machining time. Agenda: Learn about technologies that allow you to decrease machining time and simultaneously increase tool life Watch a presentation of revolutionary toolpaths generated by CAMWorks VoluMill, VoluTurn, and Sandvik Coromant’s PrimeTurning See details on the time-savings experienced on a variety of machines

This two-part webinar series will explore various levels of AI automation available in today’s manufacturing software. HCL CAMWorks will explore technologies in CAD and CAM software – along with presentations of workflows that save time during both programming and machining processes. This series will focus on ways to improve delivery times by speeding up your part programming and decreasing part machining time. Agenda: See how you can maintain the digital thread through fully integrated CAD/CAM software Watch a presentation of SolidWorks and SolidWorks CAM programming with intelligence based machining Learn about powerful application programming interfaces (APIs) that streamline programming Hear how other machine shops have experienced dramatic time-savings by implementing CAD/CAM AI automation

SUR/FIN is the primary conference and trade show dedicated specifically to the surface technology industry. It is where leading surface technology companies connect, collaborate and contribute. And because it is the only conference and trade show sponsored by the National Association for Surface Finishing (NASF)—representing the $28 billion finishing industry—it attracts noted business leaders and prominent thinkers to a forum where relevant issues are addressed and technologies presented. Join noted business leaders, visionary thinkers and the who’s who of the industry as we delve into the most pressing issues and explore the latest cutting-edge technologies. Immerse yourself in an atmosphere of networking opportunities, enriching education and unbeatable collegiality. 2024 Show Dates: Wednesday, June 5: 5:00 pm – 7:00 pm Thursday, June 6: 10:00 am – 5:00 pm Friday, June 7: 9:00 am – 3:00 pm

RAPID + TCT is returning to the west coast after a decade away! For more than 30 years, RAPID + TCT has defined the crucial role of additive manufacturing and empowered the establishment of an industry that continues to conceive, test, improve and manufacture new products at a faster, more cost-efficient pace. SME and Rapid News Publications have teamed up to produce the annual RAPID + TCT event, which takes place June 25-27 in Los Angeles, California. The event is for those who provide technology and for those who need to understand, explore and adopt 3D printing, additive manufacturing, 3D scanning, CAD/CAE, metrology and inspection technologies.

Laser powder bed fusion is the most widely used additive manufacturing method for metal part production, and electron beam melting is a closely related technology. For metalworking facilities contemplating a move into metal AM using technologies such as these, here is a road map for success. Speakers will cover materials, safety, part design, production workflow and differences between laser and electron beam metal powder bed fusion systems.

Understanding all the things that contribute to a machine’s full potential accuracy will inform what to prioritize when fine-tuning the machine.

Consider what types of implementation your shop prefers when deciding between workpiece-handling and pallet-handling automation solutions.

When getting a grip on stainless steel, make sure you are very specific in how you talk about it and understand the pertinent information you need.

Besides the linear axes X, Y and Z, 5 Axis Machining Centers also move in two rotary axes, often identified as A and B axis. The rotary axes tilt the tool with respect to the part. Physically, it can be either the tool that tilts or the part that tilts. True 5 axis CNC machining uses these axes to smoothly follow a contoured surface. This type of machining has long been important in the aerospace industry, where machined parts follow the aerodynamic forms of aircraft. Some machines move the rotary axes only to position the tool or work outside of the cut. A machine capable of this “3+2” machining often can reach all of the machined features of the part in a single setup.

Cumberland Additive’s CNC programmer in Pennsylvania spends most of his time writing programs for machine tools in Texas.

If you want to streamline production and be competitive in the industry, you will need far more than a standard three-axis CNC mill or two-axis CNC lathe and a few measuring tools.

So you’ve settled on a five-axis machine. So what options do you choose? One to remember: spindle probing.

Hermle’s first Five-Axis Summit was designed to show beginners the benefits of five-axis machining and demonstrated how more advanced users can take their capabilities to the next level with automation.

This machinist found an opportunity in a niche market and decided to learn machining and create his own business. Here's how he did it.

Choosing the right automation to pair with a CNC machine tool cell means weighing various factors, as this fabrication business has learned well.

Universal machines were the main draw of Grob’s 5-Axis Live — though the company’s apprenticeship and support proved equally impressive.

From cobots to machine monitoring, this Top Shop honoree shows that machining technology is about more than the machine tool.

Five-axis machining technology was the highlight of the Hwacheon open house in Lincolnshire, Illinois this August.

If you want to streamline production and be competitive in the industry, you will need far more than a standard three-axis CNC mill or two-axis CNC lathe and a few measuring tools.

Automation is only the tip of the iceberg for Famar, which also provides multitasking options for its vertical lathes and horizontal five-axis machine tools.

At GF’s Medical Center of Competence, the company shows off EDM and laser features that could make a large impact on medical manufacturing — and elsewhere.

Five-axis machining is enabling custom fabricator Meyer Tool to take on more complex work and helping it produce less complex jobs more efficiently.

To meet an increase in demand, this shop invested heavily in automation solutions and five-axis machines to ramp up its production capabilities.

Reinvestment in automation has spurred KCS Advanced Machining Service’s growth from prototyping to low-and mid-volume parts. The key to its success? A young staff of talented programmers.

What is a five-axis CNC machine?

Five-axis machining adds rotational movement to the traditional three axes of linear motion (X, Y and Z). These machines can incorporate an A-axis that handles rotation of the X-axis, a B-axis that does the same for the Y-axis, or a C-axis that rotates about the Z-axis. Some employ rotary, tilting tables, which provide mechanical and thermal stability alongside improved access for swarf removal. Others employ a pivoting spindle head to accommodate larger, pallet-loaded parts.

Source: Machining 101: What is Five-Axis Machining?

Besides the linear axes X, Y and Z, 5-Axis Machining Centers also move in two rotary axes, often identified as A and B axis. The rotary axes tilt the tool with respect to the part. Physically, it can be either the tool that tilts or the part that tilts.

What are the benefits of five-axis machining?

Granting users access to five sides of a part in a single setup enables tighter tolerances. Parts with 3D contoured surfaces (such as mold cavities and electrodes) tend to be great candidates for five-axis machining. For example, flexibility in accessing deep cavities enables shops to use tool assemblies with reduced lengths and aspect ratios for these operations.

Improved tool orientation control also helps with tool breakage and chatter when working with difficult-to-machine materials. For example, the surface speed of a ball mill depends on the contact angle between tool and surface. On three-axis equipment, this angle changes as machining proceeds. When the bottom of the ball mill contacts the part, surface speed becomes an unproductive zero. Surface speed then reaches its peak when the tool’s equator contacts the part. These variations in surface speed cause variations in surface finish, create premature and unpredictable tool wear, and reduce productivity.

Orientation control also boosts performance of flat-bottom and bull-nose end mills that need a constant 5- or 10-degree angle between the cutter axis and the plane normal to both the surface tangent plane and the direction-of-motion plane. The angle increases the effective radius, reducing the scallop height, improving surface finish and reducing the number of tool passes required to complete the operation. Controlling tool orientation also enables a constant depth-of-cut and accounts for variations in the stock-on condition of parts.

Source: Machining 101: What is Five-Axis Machining?

Initially operating a five-axis machine like a three-axis machine may seem like a waste of capability, but it can help users become more familiar with the machine while they learn.

What are some common types of five-axis machines?

Compound rotary tables are the most straightforward and economic way of getting five-axis performance, but they come with several significant drawbacks. These tables can be added to three-axis machine tools, but are less stiff and possess higher angular errors than more integrated approaches. Stacking the rotary axes on top of each other further magnifies angular errors, and the large stack-up between workpiece and rotary axes with a double-tilt rotary means high-torque loads affect the gear sets, reducing life and increasing deflection.

Two-axis spindle heads, also called spindle heads, typically see use on gantry-type machining centers. They suffer the same accuracy and stiffness weaknesses as double-tilt rotary tables, and can have limited rotational range (for vertical machining, the C-axis will typically have an unlimited range of motion, while the A-axis might be limited to ±90 degrees of motion from the vertical position).

The tilting spindle, when combined with a single-axis rotary table, is generally the best choice for five-axis machining of small- to mid-size concave and convex components. Prismatic and long, slender parts are particularly well-suited for this configuration. The B-axis enables the spindle to rotate around the tool tip, minimizing angular errors and keeping torsional loads on the B-axis to a minimum.

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