CNC Machine Tools News

Full 5-axis or 3 + 2 Machining: Which is Right for You?

If you currently use conventional 3-axis machining, your logical part processing progression is the step up to full 5-axis or 3 + 2 machining capabilities. While both offer advantages, understanding the fundamental differences between the two is key to determining which process will best meet your specific needs.

In simultaneous 5-axis machining, the machine tool’s three linear axes (X, Y and Z) and two rotational axes (A and B) all engage at the same time to perform complex contour surface machining. There are many advantages of full 5-axis machining, all of which significantly impact productivity and profitability. Processing five sides of a part in a single setup requires less preparation, and results in shorter lead times and better accuracy and eliminates the need to move workpieces across multiple workstations/pieces of equipment.

Undoubtedly the biggest benefit of 5-axis machining is that it raises the limits on the types of part geometries you can machine. Imagine the new business potential for your shop if you are able to machine complex automotive, aerospace or medical parts. However, not all parts require full 5-axis machining. Some are more efficiently produced using 3 + 2 machining, where the machine executes a 3-axis milling program with the cutting tool locked in a tilted position using its two rotational axes. The process, also known as 5-axis positional machining, relies on the fourth and fifth axes to orient the cutting tool in a fixed position rather than manipulate it continuously during the machining process.

As with any machining job, the size, features and tolerance requirements of your workpiece help determine which type of process to use. If your part requirements have changed – tighter tolerances and more complex geometries – you may need 5-axis capabilities. If on the other hand, you simply need a better way to position less complex parts for greater access to their features, then 3 + 2 may be the way to go.

Mazak Machine Tools

When compared with conventional 3-axis machining, 3 + 2 machining allows the use of a shorter, more rigid cutting tool that can be angled toward the workpiece surface for faster feeds and speeds. Common applications for 3 + 2 operations include roughing and other aggressive high-speed machining techniques. The shorter tool length also enables undercuts in cavities and steep walls, a capability well suited for moldmaking and other workpiece applications involving curves or angled tubular shapes.

Although not a substitute for full 5-axis machining, many shops currently using 3-axis machining find that 3 + 2 can be a great way to transition into full 5-axis machining capabilities. It provides some of the advanced capabilities without the investment in full 5-axis machines. That being said, today’s 5-axis machines are more affordable than ever before. And, an investment in a 5-axis machine tool often allows a shop to take on jobs that it was previously unable to fulfill and realize efficiencies that not only pay for the machine tool, but also generate profit.

Mazak offers a wide selection of machine tools and solutions that can meet any shop’s part-processing needs, ranging from Multi-Tasking machines that have full 5-axis capabilities such as those in our INTEGREX Series to the full simultaneous 5-axis machines in our VARIAXIS Series. In fact, the selection of 5-axis machines is so comprehensive that we have developed a 5-Axis and Multi-Tasking Machine Tool Guide called The Four Quadrants that condenses part processing into four categories to help you choose which level of technology best suits your needs and budget.

Both 5-axis and 3 + 2 machining have advantages and can help make you more profitable by improving efficiency on your current production jobs. Plus, any time you add new capabilities to your shop, you have the opportunity to expand your customer base by bidding on new, more complex work. If you’re ready to boost your part processing capabilities, contact us to discuss which level of technology best meets your needs and will help you become more profitable.

5-Axis and Multi-Tasking Machine Tool Selection Guide

Mazak offers the industry’s most advanced and comprehensive selection of 5-axis and Multi-Tasking machine configurations to give you the best cost of ownership and endless possibilities in complex part production. However, selecting the most appropriate level of manufacturing technology for your needs isn’t always easy.

That’s why Mazak have created the Four Quadrant Machine Tool Selection Guide to help you identify what Mazak equipment is going to make you the most competitive and profitable. Each quadrant represents a different level of machine capability, from traditional 5-axis performance to complex Multi-Tasking operations.

Quadrant 1

SINGLE-TABLE 5-AXIS MACHINES WITHOUT TURNING CAPABILITIES

  • Machine complex part geometries
  • Easier work area access than automated machines
  • Larger machining zones than automated machines
  • Lowest initial investment

These single-table VORTEX and VARIAXIS 5-axis machining centers bring superior surface finishes and high part quality to those processing complex geometries from titanium, aluminum and steel. And because they do not offer Multi-Tasking or include automation, these machines are the most affordable solutions within the four quadrants.

VORTEX SERIES + TILTING HEADS

  • VORTEX i-630V/6S
  • VORTEX i-800V/8S
  • VORTEX e-1060V/8S

VARIAXIS SERIES + TILTING TABLES

  • VARIAXIS i-700
  • VARIAXIS i-800

CHARACTERISTICS

  • Simultaneous 5-axis and multi-surface machining
  • New SMOOTH TECHNOLOGY
  • Broad spindle selection
  • Various tool storage capacities
  • Large machining zones
  • Easy work area access
Quadrant 2

AUTOMATED 5-AXIS MACHINES WITHOUT TURNING CAPABILITIES

  • Machine complex part geometries
  • Unattended operations
  • Off-cycle part setup
  • High-volume production

These automated VORTEX and VARIAXIS 5-axis machining centers offer the same advanced cutting performance as their single-table counterparts in Quadrant 1 but at even higher productivity levels. With the addition of a two-pallet changer or PALLETECH System, these machines provide unattended and lights-out operations.

VORTEX SERIES + TILTING HEADS

  • VORTEX i-630V/6
  • VORTEX i-800V/8
  • VORTEX e-1060V/8

VARIAXIS SERIES + TILTING TABLES

  • VARIAXIS i-700 + Two-Pallet Changer
  • VARIAXIS i-800 + Two-Pallet Changer

CHARACTERISTICS

  • Simultaneous 5-axis and multi-surface machining
  • Automation increases machine tool utilization
  • Off-cycle part setup
  • High-volume production
  • New SMOOTH TECHNOLOGY
  • Broad spindle selection
  • Various tool storage capacities
Quadrant 3

SINGLE-TABLE 5-AXIS MACHINES WITH TURNING CAPABILITIES

  • Machine highly complex part geometries
  • Single setup part production
  • Easier work area access than automated machines
  • Larger machining zones than automated machines

These single-table INTEGREX and VARIAXIS machines are a complete fusion of a 5-axis machining center and a vertical turning center. Such Multi-Tasking capabilities allow these models to process even more complex parts from titanium, aluminum and steel than the machines in Quadrants 1 and 2.

INTEGREX SERIES + TILTING HEADS

  • INTEGREX i-630V/6S
  • INTEGREX e-1060V/8S
  • INTEGREX e-1600V/10S
  • INTEGREX e-1850V/25S

VARIAXIS SERIES + TILTING TABLES

  • VARIAXIS i-700T
  • VARIAXIS i-800T

CHARACTERISTICS

  • Multi-Tasking Capabilities
  • Single setup part production
  • New SMOOTH TECHNOLOGY
  • Broad spindle selection
  • Various tool storage capacities
  • Large machining zones
  • Easy work area access 
Quadrant 4

AUTOMATED 5-AXIS MACHINES WITH TURNING CAPABILITIES

  • Machine complex part geometries
  • Single setup part production
  • Unattended operations
  • Off-cycle part setup
  • High-volume production

Similar to the machines in Quadrant 3, these INTEGREX and VARIAXIS models are the complete fusion of a 5-axis machining center and vertical turning center only they include automation to achieve even higher levels of productivity.
With the addition of a two-pallet changer or PALLETECH System, these machines provide unattended and lights-out operations. Because these machines offer the highest possible performance of all the four quadrants, they require the most investment.

INTEGREX SERIES + TILTING HEADS

  • INTEGREX i-630V/6
  • INTEGREX e-1060V/8
  • INTEGREX e-1250V/8
  • INTEGREX e-1600V/10
  • INTEGREX e-1850V/12

VARIAXIS SERIES + TILTING TABLES

  • VARIAXIS i-700/T + Two-Pallet Changer

CHARACTERISTICS

  • Multi-Tasking Capabilities
  • Automation increases machine tool utilization
  • Single setup part production
  • Off-cycle part setup
  • High-volume production
  • New SMOOTH TECHNOLOGY
  • Broad spindle selection
  • Various tool storage capacities