Multi Axis CNC Machining: The Guide To Material Selection For Complex & Cost-Sensitive Parts

Multi axis CNC machining is the key to solving this dilemma: when the geometric complexity of parts meets strict budget control, traditional manufacturing processes often find themselves in a dilemma-either sacrifice design integrity or bear high costs.

Multi axis CNC machining is a means not only of processing complex shapes, but it can be a strategy for optimizing a particular cost as well. But how can you become a master of this technology and make it a source of value for your project?

This paper will explore how multi-axis machining helps to lower total cost of process innovation, how the technology overcomes difficult-to-cut materials, and will expose how to overcome geographical constraints while selecting the right global business partner to secure a trustworthy business partner like JS Precision that will deliver the best global technology and engineering collaboration.

Figure 1:The working process of five axis CNC machining

Summary of Core Answers

Decision Dimension	Common Misconceptions	JS Precision's Solution
Cost and Complexity	Considering that multi-axis machining costs too much and can be applied to prototypes alone, without taking into account its great benefit in eliminating costs associated with processes, fixtures, and assembly by having machining accomplished in "single-setup" operations.	This work offers analysis of multi-axis machining solutions based on DFM, proving that for complex parts, five-axis machining has lower costs than traditional machining involving multiple processes.
Accuracy and Materials	With a correlation between a high degree of precision, like 5-axis machining tolerances, and conventional material processing, the influence of material properties is underrated.	Customization of strategies, tools, and cooling concepts is carried out by us for a variety of multi axis CNC materials ranging from aluminum alloys to High-Temp Alloys, while ensuring the fulfillment of the accuracy requirements.
Supplier Selection	Evaluating the capability of 5 axis CNC machining services solely in terms of the brand name of the equipment without regard to other soft skills like process experience and quality systems.	JS Precision offers more than just the latest 5 axis CNC machining center, we have comprehensive services ranging from simulation to international project management.

Key Takeaways

Multi-axis machining is known as "cost optimizer," whereby the process cuts down the cost incurred during the manufacture of the parts due to minimizing the setup process and setup-related tasks.

Accuracy comes from systems engineering: reaching the accuracy of ±0.01mm 5-axis machining tolerances involves the optimal integration of machine tools and cutting tools, temperature, processing strategies, and material properties.

Material Selection Defines the Ceiling of the Process: To machine difficult-to-cut material or to machine a composite material, a customized approach to multi axis machining must be used, generic values will not work.

Trusted Service Providers Are Involved in "Solutions": Premium 5 axis CNC machining services must be actively involved in optimizing design, with expected cost, quality, and time in mind.

China is now a World Leader in Precision Manufacture: China's component suppliers, exemplified by JS Precision, are on a par with those of Europe and America and are actually more cost-effective.

JS Precision Experience: Multi Axis CNC Machining Of Complex Parts

With over 15 years of experience in the industry for multi axis CNC machining, JS Precision has expertise based on four main sectors: Aerospace, Medical Devices, Shipbuilding, and High-End Equipment.

We have processed optical mounts with diameters of 1.2 meters for European satellite companies, mass-produced implants out of titanium alloy for American medical enterprises, and also processed propeller parts, over 5 tons, for Asian shipping conglomerates, adding up to over 100,000 complex pieces, with tolerances maintained at ±0.005mm - ±0.02mm.

In material processing, we have made progress in special solutions for cutting 12 difficult-to-cut materials and 8 types of composites. We have an average engineering team experience of more than 8 years, and we have managed to decrease the scrap rate of complex curved surface machining of titanium alloys from 18% to 0.5% for aerospace customers.

As emphasized in ASME Y14.5-2018 (Geometric Tolerance and Dimensional Labeling Standard), "the core of precision manufacturing is the coordinated adaptation of processes and materials," which is highly consistent with our practical experience.

This practical guide is the result of experience gathered from thousands of projects, with every point supported by real-life examples. If you're struggling with material selection and processing solutions for complex parts, this guide with its experience in 5 axis CNC machining can be extremely helpful.

Want to get your customized machine process plan from JS Precision for your component? Just provide us with material for your component and structural requirements, and we will provide you with our technical report concerning your component in 24 hours.

How Can Multi Axis CNC Machining Actually Reduce Your Total Expenditure?

In fact, many firms are misguided in thinking that multi axis CNC machining is more costly, while in the case of complicated components, its essential benefit of "accomplishing all machining within one setup" will be able to systematically lower down total cost of ownership from different facets.

It is essential to note that the main factor why 5 axis CNC machining is considered a cost-optimization technique is that it resolves the issues of conventional machining: "cumbersome processes, accumulated errors, and low efficiency."

Removing Cumulative Errors: Single Setup Enhances Yield and Reduces Cost of Inspection

Traditional three-axis machining needs 4-8 setups, and each change of datum causes an error of 0.02-0.05 mm, thus involving up to 10%-20% scrap rate and extra inspection costs.

Multi axis CNC machining incorporates all machining surfaces in one setup without error of datum, thus improving positional accuracy by more than 30% and maintaining scrap rate under 1% and decreasing inspection burden by 80%.

Fixtures and Processes Subtraction: "Manufacturing Fixtures" to "Direct Manufacturing"

Conventional machining involves the use of customized fixtures for each process costing thousands of dollars and taking up 30% of the total cycle time.

For the 5-axis CNC machining process, the use of universal tooling or direct material placement may be adopted. In an automotive manifold case history, universal tool sets eliminated the use of six fixture sets resulting in an 85% savings in fixture cost.

The Multiplier Effect of Time Compression: A Revolution in Efficiency for Complex Surface Machining

In the processing of complex surface parts like impellers and blades, the machining process in traditional three-axis machining involves various positioning operations, thus rendering it inefficient.

The five-axis combined function in multi axis CNC machining allows continuous processing. It took only 12 hours to process an aircraft engine impeller with a 300mm diameter, reducing machining time from 45 hours, thus increasing machining efficiency by 73%.

What Are The Critical Steps In Crafting Custom Multi-Axis Machining Solutions?

An optimal result from multi axis CNC machining is not just turning the key and "machining" but also involves an organized, cooperative effort from design through completion. The major benefit of customized multi-axis machining solutions is "proactively reducing risk and allocating resources" and, in the case of an engineer, involves involvement right away.

Step One: In-depth DFM and Manufacturability Analysis

Engineers begin by checking the 3D print and analyzing areas such as overhang, interference, wall thickness, and fillet processing. For example, optimize areas such as when a wall is too thin, from 1.2mm to 2.0mm to prevent deformation, and when right-angle corners are converted from right angles to R3 corners, among others.

Step Two: Process Planning and "Digital Twin" Simulation

With the use of highly developed CAM software like Mastercam, there is planning of the process, the creation of the ‘digital twin’, importing 3D models of machine tools, cutting tools, and the workpiece, and tool path planning, collision detection, and time estimation for machining, which removes 99% of the risks associated with machining in advance.

Step Three: Customized Fixture and Tooling Strategy Development

In the case of special structures and high precision parts, non-standard fixtures are employed to provide rigidity to the clamping mechanism, special machining tools are customized for the machining of difficult-to-machine materials.

For example, the extended-edge end mill for the machining of titanium alloys when machining deep cavities and diamond-coated machining tools for machining composite materials.

Figure 2: Applying the principle of manufacturability in CNC machining as early as possible can help simplify the production process and reduce costs.

How Does Multi Axis Machining Conquer Difficult-To-Cut Materials?

Some hard-to-cut materials like titanium alloys, Inconel alloys, and high-temperature alloys are preferably used in high-end machining because of their high strength, high toughness, and high-temperature strength, but they are very hard to machine.

Multi axis machining, with its distinct process advantages, has identified itself as one of the major technologies, and here again, developing a process strategy based on the material is very important.

Constant Optimal Cutting Angle: The Solution to Extending Cutting Tool Life

Five-axis linkage technology enables dynamic correction of workpiece and tool positioning, with its side edge fixed at the best cutting angle of 15°-30° to avoid concentrated wear. The tool life is also improved from 30 minutes to 120 minutes during the process of cutting titanium alloys.

Counter Measures for Chip Evacuation and Heat Removal: Chip Damage Prevention, Deformation Prevention

Leaning on the flexibility of multi-axis CNC machines to change the position of the workpieces, optimal chip removal path planning, and combining the internal cooling system that presses 300 bar, the cutting temperature is kept below 200 ℃ to prevent deformation and burning of the workpieces.

Low-Speed, High-Feed and Trochoidal Milling: Machining Strategies for High-Hardness Material

In the case of hardened steel and cemented carbide with HRC55 or more, low speed with high feed cutting is used to reduce the cutting force, while the use of trochoidal milling helps to remove the heat load evenly to obtain a constant cutting.

Material Type	Cutting Speed (m/min)	Feed Rate (mm/tooth)	Cutting Strategy
Titanium Alloy Ti-6Al-4V	60-80	0.1-0.15	Constant cutting angle+high-pressure internal cooling
Inconel 718	30-50	0.08-0.12	Cycloid milling+low-speed large feed
Quenched Steel HRC60	80-100	0.2-0.3	Low speed large feed+dry cutting

Have difficult-to-machine materials to machine? Let JS Precision know your material and part details, and we will come up with a customized multi axis machining process for you with a guide to the recommended cutting tools to assist you in effectively and reliably machining your difficult materials.

How Are Composite Materials Reshaping The Landscape Of Multi Axis CNC Materials?

Due to the increasing demand for lightweight high-strength materials in high-precision manufacturing, carbon fiber reinforced polymers and glass fiber reinforced polymers have emerged as key constituents of multi axis CNC materials.

These materials possess distinct anisotropic behavior compared to conventional metals. Therefore, they require unique machining conditions. Multi axis machining is considered the best option here because of its adaptability.

Challenges: Anisotropy and Delamination Risk

Due to high anisotropy and low delamination strength, composite material processing must be properly designed: milling in the fiber orientation, processing edges prior to the center, appropriate feed at 0.05-0.1mm per tooth, and maintaining delamination at 1% or lower.This is highly consistent with the requirements for interlayer damage control in ASTM D3518.

Specialized Tools and "Burr-Free" Machining Process

With diamond-coated tools, compression spiral end mills, and polycrystalline diamond (PCD) tools, and by using ultrasonic vibration-assisted machining technology, there is "burr-free" cutting of composites.

Integrated Machining: "One Stop" Service - Starting Material Through to Finished Part

Performing contour milling, drilling, chamfering, and backing operations on composite materials in one set-up. In the aerospace study on a carbon fiber wing spar, all operations done in a single set-up achieved a dimensional accuracy of ± 0.02 mm, shortening the processing cycle by 40 percent.

Figure 3: The unique structural characteristics and excellent cost-effectiveness of composite materials make them highly valuable materials in many industries.

How To Consistently Achieve 5-Axis Machining Tolerances Within ±0.01mm?

The 5-axis machining tolerances of ±0.01mm are a fundamental prerequisite for elite-level manufacturing. This is not merely a function of advanced, highly accurate machine tools, but much more a function of integrative management of a multitude of variables such as environment, equipment, process, and tools. JS Precision has developed a process to achieve micron-level tolerancing.

Environment and Thermal Stability: The Key Starting Point for Precision

There is a constant temperature workshop of 20±0.5℃, and preheating for 30 minutes prior to processing is adopted for the machine tool. In-machine measurement and compensation technology is employed for long-term tasks to compensate for the effects of thermal expansion, which provides a fundamental guarantee for 5-axis machining tolerances.

Micro-Management of Tooling and Clamping Systems

High-precision hydraulic and shrink-fit tool holders with runout errors not exceeding 0.002mm are employed, and corresponding tools are selected according to the materials, vacuum chucks are employed for small parts to prevent deformation, while multi-point positioning for large parts is employed to keep the clamping rigidity high.

Process Strategy: The Art of Roughing, Semi-Finishing, and Finishing

The operation is carried out in three stages to relieve the material of stresses:

The roughing operation involves heavy depth of cut and low feeds to remove excess material, leaving 2 – 3mm stock for semi-finishing, semi-finishing helps to remove the work hardened layer, leaving only 0.1 – 0.2mm stock for finishing, finishing involves light depth of cut and heavy feeds to provide excellent surface finish and accuracy of size.

How Does a 5 Axis CNC Lathe Tackle The Machining Of Giant Marine Propellers?

With sizes ranging in diameter from several meters to tens of meters, and with heavy weights of tens of tons, along with intricate curved surfaces, giant marine propellers are the ultimate test in terms of the application of 5 axis CNC lathe.

JS Precision's Ultra-Large 5 axis CNC lathe (Turning & Milling Composite Center) has been successful in overcoming this challenge with its ability in ultra-large workpiece handling, heavy cutting, as well as five-axis linkage precision milling.

The Art of Clamping and Balancing Giant Workpieces

A dedicated chuck and tailstock support system with the largest possible clamping diameter of 5 meters is made to keep the workpiece from shifting during the machining process. Dynamic balancing tests have been conducted for the workpiece, and balancing weights have been employed to cancel the centrifugal force errors with an accuracy level of G2.5 grade.

Heavy Duty Cutting and Precision Forming Challenges

Rough machining involves removing a substantial amount of material from the copper alloy, and maximum torque is 1500 N·m.

While precision machining involves carrying out surface machining with an accuracy of ±0.02 mm by adopting a "segmented machining" approach after performing rough machining of the curve, stress relief, and then semi-finishing and finishing machining to eliminate problems of deformation.

In-Machine Measurement and Compensation: Ensuring Accuracy for Extra-Large Sizes

In order to measure the profile, thickness, and pitch of the blade, an integrated high-precision probe system is applied in real time during machining. Incorrect dimensions are auto-corrected in the tool's path so that the propeller with a diameter of several meters, as well as the blade profile, meets dimensions with a tolerance limit of ±0.03 mm.

Have you got oversized and complicated parts for machining? Call JS Precision and share information regarding the size, weight, and precision requirements of the parts to be machined, and we will design a specialized solution involving the machining capabilities of the 5 axis CNC lathe machine for overcoming the challenges posed by the manufacturing of very large parts.

Figure 4: 5-axis NC machining of marine propeller

Case Study: How Can Multi-Axis CNC Machining Reduce The Weight Of Satellite Optical Brackets By 60% And Save 55% In Costs?

Background and Challenges:

The support structure of the optical satellite producer with high resolution was intended to be composed of 28 components with aluminum alloy 6061, with 320 fasteners. The issues with this structure include cumulative tolerances of more than ±0.1 mm, assembly time of 40 hours, and weighed 12 kg, which is much more than the expected 8 kg.

JS Precision Solution:

• Design Reconstruction: Engineers were involved during early design stages to take advantage of topology optimization, lattice structures, and merge all 28 components into a single, light-weighted structure made from 7075-T7351 aerospace aluminum, featuring 12 internal conformal flow paths and 8 irregular surfaces.
• Process Innovation: Employing a large 5 axis CNC machining center, all machining operations are performed in one setup from a 25kg billet of aluminum, with a constant cutting angle to avoid deformation, accompanied by a strong internal cooling system.
• Precision Assurance: Machining is carried out under a fixed temperature of 20±0.5℃, with compensation every 6 hours through measurement done within the machine. Critical mounting surfaces are ±0.008mm flat and have a positional accuracy of ±0.015mm.

Results:

The number of components was minimized from 28 to 1, the weight considerably reduced to 4.8kg (a reduction of 60%), the overall cost of manufacture was cut down by 55% (reduced from $2800 to $1260 per item), the time of delivery was reduced by 65%, and stiffness and temperature resistance were enhanced by 40%, which satisfied requirements for space applications.

Have a desire for weight and cost reduction in your complex parts? Click to learn more about our industry case studies with JS Precision, or share with us your part requirements, and we can work with you on a multiple axis machining optimization solution.

Why JS Precision Is Your Trusted Partner For Advanced 5 Axis CNC Machining Center Projects

When it comes to high-performance multi axis CNC machining, selecting an agent is not only the selection of equipment, but also the selection of the solution and the level of quality. JS Precision, through its technical superiority, specialized personnel, and digital services, has become one of the reliable suppliers of 5 axis CNC machining services.

Technological Ecosystem: not just a cluster of high-end machine tools

Our company has 20 imported German and Japanese top-class 5 axis CNC machining centers and 8 large 5-axis CNC lathes. This allows us to provide a "one-stop" service for machining and subsequent operations. Our company also has coordinate measuring machines and laser interferometry devices.

Talent Engine: An Engineer-Driven Manufacturing Culture

We have 45 senior process engineers and programmers who have an average of more than 8 years of experience, and 12 of them have attained Mastercam advanced certification. These individuals are involved in design discussion right from the early stages of the project and help eliminate problems associated with machining non-cuttable materials and surface tool paths.

Digital Commitment: Transparent, Collaborative, and Predictable Project Delivery

Thus, we have developed a digital project management platform, where customers can access process analysis, quotes, scheduling, processing, and inspection report statuses through their personal log-in details. Customers are notified through notifications at key points of time, and this approach has led us to a customer re-purchase rate of 85%.

Contact us now by phone to gain access to our free service hotline of DFM analysis. Whether you require prototyping, small batch orders, or mass production, our 5 axis CNC machining center is dedicated to offer you effective 5 axis CNC machining services.

FAQs

Q1: Is 5-axis machining always more expensive than 3-axis machining?

Not necessarily. For complex components, single 5-axis machining may cost less than 3-axis machining because it saves on multiple setups and tool changing times, with a significantly improved yield rate. Cost-wise, it would be even more beneficial.

Q2: What is the concentricity of my parts, and can multiple-axis machining satisfy that? My parts need a concent

Yes. This is the exact core benefit that multi-axis machining offers in one setup. By doing the machining for all the holes that require concentricity in one setup itself, we can minimize errors due to datum conversion and ensure the concentricity specification of +0.02mm.

Q3: How do I check that you are able to meet the specified tolerance ±0.01mm?

We may be able to offer reports on machine calibration and process capability study (Cpk) information. Additionally, we offer full-dimensional inspection of the first part with a CMM, with a comprehensive report, to show with actual data the capability we have for machining.

Q4: How long does it take to receive a preliminary plan and quotation after supplying an STP file?

If there is regular complexity involved in the query, we typically offer a proposed scheme within 24-48 hours, including analysis, material suggestions, processing time, and a clear quote. For complicated parts, we will notify you in advance regarding the required processing time.

Q5: How do you ensure accuracy consistency across large parts?

On the high-rigidity machine tools, we depend on environmental control in our constant-temperature laboratory, while in-machine measurement systems are used for segment machining. This compensates well for accumulation of error in the machining process when large distances of travel are involved.

Q6: How do you prevent vibration and rust when shipping large, precision parts from China?

To retain the workpieces, customized foam lining or vacuum-formed trays are used, and then protective film is applied where precision surfaces exist, and VCI anti-rust packaging is employed finally before being boxed in wood. Shipping insurance is available from beginning to end so that the pieces can be delivered perfectly.

Q7: Do you support all phases from Prototyping to Small Batch Production to Mass Production?

We have prototyping and pilot lines for our flexible manufacturing units and mass production lines for our large-scale manufacturing units. Thus, we are ready to provide prototyping and mass manufacturing services with consistency in technical and quality processes throughout different stages to serve you better in different stages.

Q8: Are you involved in feasibility pre-assessment of highly complex parts?

We do offer free DFM analysis services. Before an order is placed, you are free to send your part drawings and technical requirements so that an analysis and opinions on manufacturability and risks and ways to optimize are provided.

Conclusion

The ideal combination of material choices and multi axis CNC machining is the solution to the problems posed by the production of complex and economical parts.

Selecting technology and technology partners is not only an issue of choosing the processing technology, but also choosing an improved, more reliable, and competitive cost process in terms of realising your end product.

The time has come to get the best possible insights for your complex designs.

Today, visit the website for JS Precision and upload your part drawings. In addition to providing a competitive price for your project, you'll also be given a "Design and Process Optimization White Paper" that's been put together with care by our team of experts on the ways by which our multi-axis machining solutions can help cut costs and improve efficiencies.Together, let us make difficult blueprints into brilliant reality.