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What's the difference between 5-axis 3+2 and 5-axis simultaneous control?
Release date:
2021-10-28
1.3+2 Position Machining When running a 3-axis milling program, the two rotary axes of a 5-axis machine are used to hold the cutting tool at an angled position—this is precisely why it’s called 3+2 machining technology. Similarly, 4-axis and 5-axis machines are also referred to as "5-axis machines," as their operation involves non-continuous movements, instead relying on fixed positions to determine the orientation of the cutting tool during machining. The principle behind 3+2 positioning machining essentially enables three-axis functionality at specific angles (hence the term "positioning"). In short, after the machine rotates to a particular angle, it can then proceed with standard 3-axis machining operations. 2. What Is Five-Axis Simultaneous Machining? According to ISO standards, when describing the motion of numerically controlled machines, a left-handed Cartesian coordinate system is employed. In this system, the axis parallel to the spindle is defined as the Z-axis, with an additional V-axis added for reference. The rotational coordinates around the X, Y, and Z axes are designated as A, B, and C, respectively. Typically, five-axis simultaneous machining refers to the linear interpolation motion involving all five coordinates: X, Y, Z, A, and B. 3. Differences Between 3+2 Positioning and Five-Axis Simultaneous Machining While both 3+2 positioning and five-axis simultaneous machining cater to different industry needs, they serve distinct purposes: five-axis simultaneous machining is ideal for complex surface machining, whereas 3+2 positioning excels in flat-surface applications. Advantages of 3+2 Positioning Machining: 1) Shorter tool paths lead to higher rigidity, allowing for the use of sturdier cutting tools—perfect for those working with UG programming resources. 2) The tool can be positioned at an angle relative to the workpiece surface, enabling the spindle head to extend lower and get closer to the part. 3) Reduced tool travel distances result in shorter program codes and faster machining cycles. Limitations of 3+2 Positioning Machining: 3+2 positioning is often set at a fixed angle relative to the spindle. For intricate parts requiring multiple angled views to cover the entire workpiece, this approach may lead to overlapping tool paths, ultimately increasing machining time. Advantages of Five-Axis Simultaneous Machining: 1) Eliminates the need for specialized fixtures, significantly reducing fixture costs and minimizing the number of required clamps, thereby enhancing mold machining precision. 2) Decreases the overall number of fixtures needed for the process. 3) Reduces reliance on specialized tools, lowering tooling expenses. 4) During machining, the effective length of the cutting edge can be increased, which helps minimize cutting forces, extend tool life, and cut down on operational costs. Limitations of Five-Axis Simultaneous Machining: 1) Compared to 3+2 positioning, the spindle’s rigidity is slightly compromised. 2) There are instances where employing a five-axis system isn’t advisable—for example, when using excessively short tools or oversized tool holders, as certain tilt angles could inevitably cause vibrations. 3) Compared to traditional three-axis machines, five-axis systems tend to produce slightly higher machining accuracy errors. Five-axis simultaneous numerical control represents a sophisticated integration of computer control, high-performance servo drives, and advanced machining techniques. It’s a highly challenging yet widely applicable digital control technology designed for the automated processing of complex curved surfaces. Internationally, five-axis CNC technology is regarded as a key indicator of a nation’s level of automation in manufacturing equipment. Due to its critical importance—particularly in sectors like civil aviation—and its inherent technical complexity, Western industrialized nations have historically classified five-axis CNC systems as strategic materials subject to strict export licensing regulations.
1.3 + 2-position machining
When running a 3-axis milling program, the two rotary axes of a 5-axis machine are used to hold the cutting tool at an angled position—this is also why it’s called 3+2 machining. Similarly, 4-axis and 5-axis machines are referred to as 5-axis machines because their axes don’t move continuously during machining; instead, they remain fixed in specific positions to define the tool’s orientation.
The principle of 32-position machining essentially enables three-axis functionality at a specific angle (i.e., "positioning"). In short, after the machine tool rotates to that angle, it can still perform machining in the conventional 3-axis mode.
2. What is 5-axis simultaneous machining?
According to ISO standards, a left-handed Cartesian coordinate system is used when describing the motion of numerically controlled machines. In this system, the axis parallel to the main spindle is defined as the Z-axis, with an additional V-axis added. The rotational coordinates around the X, Y, and Z axes—used for free-form CNC processes—are designated as A, B, and C, respectively. Typically, 5-axis simultaneous control refers to linear interpolation motion involving five of these coordinates: X, Y, Z, A, and B.
3.3+2 Positioning vs. Five-Axis Simultaneous Control: The Difference
3+2 positioning machining and 5-axis simultaneous machining serve different industry applications: 5-axis simultaneous machining is ideal for surface machining, while 3+2 positioning machining is better suited for planar machining.
Advantages of 3+2 positioning machining:
1) Shorter version, Official Account: You can use UG programming's "Rigorous Cutting Tools" for higher rigidity.
2) The tool can be positioned at an angle to the surface, and the spindle head can extend lower, bringing it closer to the workpiece.
3) Short tool travel distance, minimal program code.
Limitations of 3+2 positioning processing:
3+2-axis machining is typically performed at a constant angle relative to the spindle. Complex workpieces may require multiple tilted views to fully cover the entire part, but this could lead to overlapping tool paths, thereby increasing machining time.
Advantages of 5-axis simultaneous machining:
1) No special fixtures are required during machining, reducing fixture costs, eliminating the need for multiple fixtures, and improving mold machining accuracy.
2) Reduce the number of fixtures used.
3) Eliminate many specialized tools from the machining process, thereby reducing tooling costs.
4) During machining, the effective cutting edge length of the tool can be increased, reducing cutting forces, extending tool life, and lowering costs.
Limitations of 5-axis simultaneous control:
1) Compared to the 3+2 positioning, spindle rigidity is slightly reduced.
2) Sometimes a five-axis system shouldn’t be used—for example, when the tool is too short or the tool holder is too large, making it impossible to avoid vibrations regardless of the tilt angle.
3) Compared to three-axis machines, machining accuracy has a larger error margin.
Five-axis simultaneous digital control combines computer-based control, high-performance servo drives, and advanced machining technologies, making it a highly challenging yet widely applicable digital control technique for the automated processing of complex curved surfaces. Internationally, five-axis CNC technology is regarded as a key indicator of a nation's level of automation in manufacturing equipment. Due to its critical role—particularly its significant impact on the civil aviation industry—and its inherent technical complexity, Western industrialized nations have historically classified five-axis CNC systems as strategic goods, subjecting their export to strict licensing requirements.
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