How To Use 5 Axis Robotic Arms For Machining: A Guide For Aerospace Manufacturing And Supplier Selection

A 5 axis robotic arm is one of the main tools in aerospace manufacturing, and it is revolutionizing the production process by overcoming the limitations of traditional machining.

For instance, conventional gantry milling machines are unable to reach the tiny internal cavities of complex parts like integral bladed disks and landing gear joints, whereas standalone machine tools have long return on investment periods.

An adaptable articulated robotic arm can get deep into parts for cleaning and in-situ machining, thus greatly increasing the work turnaround.

Here we will look at how it can be used for the resolution of molding problems and, taking into account the benefits of 5 axis CNC machining, provide the enterprises with suitable machining solutions.

Core Answer Overview

Core Dimensions	Key Conclusions
Selection Logic	For pure cutting, take a 5 axis robot arm, for multi-tasking, take a 6 axis industrial robot arm.
Technical Advantages	5 axis simultaneous machining can shorten the tool overhang by 30%, help to suppress chatter, and also improve chip removal.
Supplier Evaluation	The main criteria should be thermal stability, AS9100 certification, and examples of machining similar aerospace components.
Rigidity Performance	When titanium alloys are milled, the 5 axis robotic arm's end-effector vibration is lowered by around 40% compared to a 6 axis arm.
Process Efficiency	5 axis simultaneous machining can eliminate some setups, thus impeller disk machining efficiency overall can be enhanced by more than 25%.
Supplier Metrics	A repurchase rate >30% is one of the major signs of reliability when looking at the top 5 axis machining center manufacturers.

Key Takeaways:

• Rigidity equals accuracy: end-effector vibration of the 5 axis robotic arm is reduced by approximately 40% when titanium alloys are milled, compared to a 6 axis arm.
• Process either determines success or failure: 5 axis simultaneous machining helps to reduce the number of setups, thus the overall impeller disk machining efficiency can be raised by more than 25%.
• Data is the basis of trust: a repurchase rate >30% is one of the key indicators of reliability when one is looking at 5 axis machining center manufacturers.

Why Trust This Guide? JS Precision's Experience In 5-Axis CNC Machining Services

Every single conclusion in this article was drawn from JS Precision's more than 15 years of hands-on experience in 5 axis CNC machining, as well as its efficient execution of machining services for over 200 aerospace companies worldwide.

We have successfully machined more than 1000 types of aerospace components with 5 axis, covering core components such as integral bladed disks and landing gear supports, which have directly relieved the pain points of aerospace machining.

In the usage of 5 axis robotic arms, we went all the way from equipment selection and process debugging to mass production implementation, and we came up with standardized solutions for difficult-to-machine materials like titanium alloys and Inconel 718 high-temperature alloys (ISO 9001:2015 certification gives a strong basis for quality assurance throughout the entire process.)

We assisted a European aerospace company in overcoming the vibration issue in machining integral bladed disks, which led to a decrease in their product scrap from 18% to 0.5%.

Besides that, we have also done on-site machining of ultra large cabin structures for domestic aerospace research institutes, thus, the institutes have saved over $500, 000 on equipment transportation and secondary clamping costs.

With regard to the integration of 5 axis solutions, we are able to offer bespoke solutions from prototype to full-rate mass production depending on the customer's production scale. On top of that, we have core process optimization methods for 5 axis simultaneous machining, which can increase the tool life by 40% on average.

This manual covers the technical aspect as well as a compilation of our hands-on experience to a large extent, thus assisting companies in steering clear of mistakes in selection and processing.

Want to quickly find a suitable 5 axis robotic arm machining solution? Contact JS Precision engineers now, tell them your component material and machining requirements, and you can get a free customized process planning sheet.

Why Choose An Articulated Robot Arm Over Traditional CNC For Complex Aerospace Components?

Traditional 5 axis CNC machining equipment is not very flexible and can only machine complex aerospace components to a limited extent. Articulated robot arm, together with the technological advantages of 5 axis robotic arms, can solve these problems in the following three ways:

1.Accessibility, and Obstacle Avoidance:

Traditional machine tools are fixed by their shapes and thus are unable to get into complex cavities, articulated robot arm, due to their multi-joint structure, can avoid the collision, and 5 axis robotic arms can accurately place the machining head to the very small openings.

2.Ultra-large component machining in-situ:

It is impossible to machine ultra-large cabins using traditional machine tools. A 5 axis robotic arm can be installed on an AGV for mobile machining, thus secondary clamping is not necessary. When combined with 5 axis CNC machining, tolerances are assured (ANSI/RIA R15.06-2012 safety standards).

3.Cost advantage of small batch production:

Small batches of aerospace components with a large variety are produced. Dedicated machine tools involve high costs of investments and low usage rate, a 5 axis robotic arm is only 60% of that and offers multiple uses and an investment return of over 30%.

Want to verify the suitability of an articulated robot arm for machining your components? Send your component CAD drawings to JS Precision, and we will provide a free machining feasibility analysis and match a suitable 5 axis robotic arm model.

5 Axis Robot Arm Vs. 6 Axis Industrial Robot Arm: Which One Delivers The Precision You Need?

In aerospace machining, the number of axes is what defines the precision and efficiency. The fundamental differences between a 5 axis robot arm and a 6 axis industrial robot arm are mainly rigidity and machining adaptability as explained below:

1.Reasons why 6 axis is not suitable for counterweight cutting:

A 6 axis industrial robot arm is perfect for assembly and handling things and it can reach vibration level as low as 0.02mm when cantilever milling titanium alloys, a 5 axis robot arm is a compact and rigid structure, vibration of the end, effector is reduced by about 40% when compared to a 6 axis arm.

2.The main reason behind 5 axis simultaneous machining to achieve surface finish:

5 axis simultaneous machining is the heart of aerospace turbine disk machining. A 5 axis robot arm is capable of finishing complex curved surfaces in one go, a surface roughness of 8 microinches can be attained, which is better than 6 axis machining.

Want to accurately determine whether a 5 axis robot arm or a 6 axis industrial robot arm is more suitable for your machining task? Submit your machining requirements to JS Precision now, and we will provide a free professional assessment of your axis selection, along with a process precision assurance solution.

How Does 5 Axis Simultaneous Machining Solve Aerospace Material Challenges?

Turning aerospace materials poses high challenges in the first place. Technology of 5 axis simultaneous machining helps 5 axis robot arms to solve these problems and eventually, 5 axis machining aerospace components becomes to be mainstay:

1.Shortening Tool Overhang, Conquering Deep Cavities and Thin Walls:

Conventional machining tools with overhangs beyond 150mm have a high chatter risk. 5 axis simultaneous machining can reduce the overhang by 30%, thus it is Inconel 718 high-temperature alloys deep cavities stable machining that is ensured.

2.Improving Chip Removal and Heat Dissipation, Handling Thin-Walled Aluminum Alloy Parts:

5 axis simultaneous machining is able to control the posture of the tool that gives rise to less deformation and, when high-pressure coolant for chip removal is used, the net forming is realized which cuts material waste by 15%-25%.

3.Process parameters for 5-axis simultaneous machining of different aerospace materials:

Material Type	Tool Rotation Speed ​​(r/min)	Feed Rate (mm/min)	Tool Overhang (mm)	Surface Roughness (µ inches)
Titanium Alloy Ti-6Al-4V	1200	150	80	10
Inconel 718	800	100	70	12
Aerospace Aluminum Alloy 7075-T6	3500	500	90	6
Carbon Fiber Composite Material	2000	200	60	8

What Specific 5 Axis Machining Aerospace Components Demand The Most From Your Robot?

Different 5 axis machining aerospace components require 5 axis robot arms with different performance features. The suitable 5 axis solutions should each be centered on their own main points.

The key component requirements are as follows:

• Integral Bladed Disks (Blisks): The blades are thin and sharply twisted, so they require the dynamic response of the 5 axis robot arm to be very strong and the interpolation accuracy must be 0.001mm in 5 axis simultaneous machining.
• Landing Gear Bracket: Large titanium alloy parts involve a lot of machining operations, thus, 5 axis solutions should be of high rigidity and excellent chip removal capability, the spindle torque should be at least 80 N·m.
• Mars Rover Actuator Base: By using special materials and only allowing a tolerance of ±0.0002 inches, the 5 axis robot arm has to be equipped with a laser interferometer compensation system.
• Composite Material Fuselage Panels: Non-metallic materials that are very difficult to machine, the 5 axis robot arm should be equipped with a dedicated dust extraction device and sealing treatment.

Figure 1: Two white five-axis robotic arms are simultaneously working on opposite sides of a large metallic aerospace component in an industrial setting.

How To Evaluate 5 Axis Machining Center Manufacturers: Beyond The Spec Sheet

Choosing reliable 5 axis machining center manufacturers is essential for aerospace machining quality. One cannot just rely on the specification sheet alone but should thoroughly assess core components, application cases, and quality systems.

High quality manufacturers can offer full 5 axis solutions that guarantee stable machining.

1.Core Component Traceability:

A point to consider while assessing 5 axis machining center manufacturers is to ask about the brand of the spindle, guide rails, lead screws, and control systems. High-quality spindles can manage thermal deformation control within 0.002 mm.

2.Application Cases and Process Verification:

It is a requirement for the 5 axis machining center manufacturers to produce similar machining videos, especially focusing on titanium alloy chip breaking and internal cooling technology. Manufacturers who have experience in batch processing possess more mature processes.

3.Quality System and On-site Inspection:

AS9100 certification is a basic requirement. It is necessary to conduct on, site inspections of the testing equipment. Suppliers with a repurchase rate >30% offer more stable after-sales services and have lower cooperation risks.

Core Evaluation Indicators and Standards for 5 Axis Machining Center Manufacturers

Evaluation Indicators	Core Requirements	Pass Standard	Excellent Standard
Core Components	Spindle/Guide/Control System Brand	First-tier brand assembly	Original factory customized core components
Machining Cases	Aerospace component machining experience	10+ cases	50+ batch processing cases
Quality Certifications	Aerospace related certifications	AS9100 basic certification	AS9100D+NADCAP certification
Testing Equipment	Precision testing equipment configuration	CMM coordinate measuring machine	3D blue light scanner + laser interferometer
Customer Repurchase Rate	Percentage of existing customers	≥20%	≥30%
After-sales Response	Fault handling time	Within 48 hours	24-hour on-site service

Figure 2: A technical diagram of a blue six-axis industrial robot arm against a white background, with all its rotational joints clearly numbered for evaluation.

What 5 Axis Solutions Exist For Scaling From Prototyping To Full-Rate Production?

In aerospace manufacturing, the call for flexible and automated 5 axis solutions continues to rise from prototyping through to mass production. Digitally, facilitated 5 axis simultaneous machining supports a smooth process integration and helps fully exploit the 5 axis robot arm.

1.Digital Twins and Offline Programming

5 axis systems with offline programming capability are the very backbone of the future. Siemens Sinumerik One control system has the feature of virtual machining simulation, thereby enabling proactive collision prevention and reducing trial cutting costs by 60%.

2.Flexible Manufacturing System Integration

Highly efficient 5 axis solutions should be capable of seamless integration with a pallet storage or loading/unloading system for achieving 24/7 unmanned machining that, in turn, boosts the utilization of the equipment to more than 90% and increases the efficiency of mass production by 40%.

3.CAM Software Collaboration

The post-processing of the 5 axis robot arm should be compatible with all the mainstream CAM software. Sophisticated toolpath techniques not only help in extending the tool life by 50% but also in substantially reducing the cost of machining high-temperature alloys.

Why Choose JS Precision For Your 5 Axis Machined Aerospace Components?

JS Precision is a leading manufacturer of reliable 5 axis machining centers and also one of the best 5 axis machining aerospace components service providers. To deliver full-service end-to-end machining, we combine 5 axis CNC machining and 5 axis robotic arm technologies at a deep level.

1.Hard Power:

JS Precision is the owner of several imported 5 axis machining centers from Germany and Japan, plus they are also equipped with German Kessler electric spindles, thus achieving positioning accuracy of ±2µm. Customized 5 axis robotic arms can satisfy varied machining requirements.

2.Certifications and Case Studies:

JS Precision is certified to AS9100D and ISO 9001:2015 standards, and the components that it manufactures for the aerospace industry are already implemented in several aerospace devices, with more than 500 batches done.

3.End-to-End Service:

JS Precision offers CAM programming and flexible scheduling from prototype to mass production and has mastered the core technology of 5 axis simultaneous machining to guarantee the delivery of components of the right quality and on time.

4.Transaction Guarantee:

JS Precision has a repurchase rate exceeding 35%. Besides that, they offer double guarantees of both the money and the delivery time. All machined parts are accompanied by full inspection reports to make sure that the precision meets the standards.

Want to experience professional 5 axis machining aerospace components processing services? Upload your CAD drawings to JS Precision to receive a free DFM manufacturability analysis and detailed quote, with no hidden costs.

JS Precision Case Study:Overcoming The Challenge Of Deep Cavity Vibration In Aerospace Titanium Alloys

Challenge

One domestic aerospace institute seriously has a need to machine a batch of titanium alloy deep cavity supports for landing gear. The components have a cavity depth of 120mm and the wall thickness is only 3mm.

6 axis industrial robot arms with a traditional design constantly exhibited vibration modes during machining due to their long overhang and lack of rigidity, which resulted in a scrap rate of 15%.

Moreover, the machining time for one piece was longer than 8 hours, so the delivery time requirements were not met. At the same time, traditional 5 axis CNC machining equipment was incapable of in, situ machining which caused high transportation costs.

Solution

1.Equipment Reconfiguration:

A JS Precision 5 axis robotic arm machining center was selected. Its high-rigidity cast iron bed has a flatness error ≤0.002mm/m, and the compact 5 axis head achieves a repeatability accuracy of ±0.001mm.

The tool overhang was shortened from 130mm to 90mm, thus the machining chatter was reduced from 0.02mm to within 0.005mm, which greatly enhanced the stability of the machining process.

2.Process Optimization:

By deploying 5 axis simultaneous machining technology, we dynamically changed the tool orientation to keep the cutting force within the desired range of 800-1000N. Also, during the process, the cutting force direction was ensured to always point towards the workpiece area with the strongest rigidity.

On the other hand, cutting parameters were optimized, the cutting speed of titanium alloy Ti-6Al-4V was set at 1200r/min, the feed rate was 150mm/min, and the depth of cut was kept at 0.2mm.

3.Simulation Verification:

The Siemens Sinumerik One virtual machining environment was used to simulate the whole process from roughing to finishing.

Feed rate fluctuations were kept within 5%, three potential collision risks were proactively avoided, and the scrap rate during the trial cutting phase was reduced from 15% in traditional machining to 0%, thus improving the trial cutting efficiency by 40%.

Results

The modification has brought tool vibration down to no more than 0.005mm, the first-pass yield has skyrocketed from 85% to 99.8%, and the time for single-piece machining has been trimmed by 20% down to 6.4 hours, thus facilitating the customer to finish their quarterly delivery target 15 days ahead of schedule and save over $200, 000 equipment transportation and re-clamping costs.

Want to solve your aerospace component machining challenges? Call JS Precision's technical hotline now, describe your machining pain points in detail, and we will customize a solution for you, while providing free process debugging guidance.

Figure 3: A close-up of a finished, complex-shaped titanium alloy bracket with a deep cavity, designed for aerospace landing gear applications.

FAQs

1.Are 5 axis robotic arm and 5 axis CNC machine tool totally different?

Not totally different. 5 axis robotic arms are multi-joint robotic arms, highly adaptable to live and complicated cavity machining. And 5 axis CNC machine tools are more resistant to high-precision batch cutting.

2.Is 5 axis simultaneous machining compulsory for manufacturing titanium alloy impellers?

Definitely so. 5 axis simultaneous machining is by far the best way to manufacture titanium alloy impellers where finishing of one fixture can be achieved and precision loss of secondary fixture is avoided.

3.How much 5 axis machining can save on the material cost?

5 axis machining lays out the workpiece path in an ideal way and also cut down the generation of scrap pieces. E.g, for thin, walled aerospace aluminum alloy parts, the scrap can be cut down by 15%-25%, and the material usage for titanium alloy parts machining can be even more than 70%.

4.What does RTCP stand for? Is it important?

RTCP stands for Rotary Tool Center Point. Only the tool-workpiece contact point has to be considered when programming. It is an essential benchmark of 5 axis solutions and basically influencing machining accuracy.

5. What methods can I use to verify that the supplier's 5 axis machining aerospace components are AS9100 compliant?

Suppliers are required to provide AS9100D certification, quality control processes, and testing reports, and AS9100 processing records for similar components can also be requested.

6. What 5 axis machining center manufacturers give the best value for a small, batch aerospace component prototype?

A multi-process flexible manufacturing service provider (FMS) is probably the cheapest way to go. They completely remove the need to pay for dedicated fixtures, rapid prototyping and 5 axis simultaneous machining are readily available to them.

7. What is the highest accuracy you can get in 5 axis machining?

Under the conditions of a temperature, controlled workshop, a micron, precision 5 axis robotic arm paired with laser interferometer compensation can consistently attain a tolerance level of 0.005mm, thus fulfilling the stringent specifications of critical aerospace components.

8. What is the normal lead time for JS Precision?

JS Precision commits to 10-15 working days lead times for standard aerospace aluminum alloy parts. Complex titanium alloy and precision aerospace components manufacturing will be assessed for their complexity of the process.

Summary

Choosing the appropriate 5 axis solutions can be crucial in aerospace manufacturing. 5 axis robotic arm plus 5 axis simultaneous machining technology can help in breaking the limitations of traditional machining. Component machining, material cutting, and equipment selection are three factors that affect the quality and cost of processing.

Through case studies, technology, and services, JS Precision has rich experiences in this domain and offers enterprises one-stop machining solutions.

Send us your CAD drawings now, and let us turn the most complicated aerospace parts into reality, using precision machining technology to bring a new level to aerospace manufacturing.