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DEMYSTIFYING 5-AXIS MACHINERY
1.0
Like many manufacturing technologies, 5-axis CNC
machining has the potential to help users improve
productivity and profitability. However its not for ev-
eryone. So how do you know if investing in a 5-axis
machining center makes sense for your operation?
Obviously, much depends on the kinds of workpieces
you typically machine, the industries you serve, the
intensity of the competition, and the demands of
your customers.
Among the industries that rely on 5-axis machining
to produce complex parts or simply improve their
manufacturing efficiencies are: Aerospace, Aircraft,
Automotive, Firearms, Off-road Equipment, Motors-
ports, Medical, Oil Field, OEM Machinery, Wind Power
Generation, Marine and Die Mold. Additionally, any
large equipment or prototype manufacturers can also
benefit from 5-axis machining.
We often find that there is some confusion about pre-
cisely what 5-axis machining is, what it does and
what the benefits are for manufacturers. This paper
will address these issues and present real-world case
studies to give you the fundamental information you
need to determine if adding 5-axis machining makes
sense for your particular business.
DEMYSTIFYING 5-axis MACHINERY
5-AXIS MACHINING DEFINED
When manufacturers think of 5-axis machining, what
most often comes to mind is 5-axis simultaneous
machining, which means that all 5 axes are engaged
at the same time to perform complex machining of
such parts as turbine blades, impellers and aerospace
airframes. Machining these kinds of parts requires all
5 axes (3 linear and 2 rotary) to
move at the same time during
the cutting process to achieve
the desired geometry. Here are
a few examples:
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above: impeller
above: turbine blades
TYPES OF 5-AXIS CNC
MACHINES
There are three basic
types of 5-axis machines:
(1) Trunnion, or Table/
Table; (2) Head/Table; (3)
Head/Head. Vertical and horizontal milling-based
machines are available in all three configurations,
while vertical and horizontal turning-based machining
centers use only the head/table concept. In milling
machines the three configurations look like this:
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DEMYSTIFYING 5-AXIS MACHINERY
2.0
5-AXIS MACHINING DEFINED (CONT.)
Another form of 5-axis
machining is 3 + 2, or
5-axis positional machin-
ing. In this type of 5-axis
machining, one or more
of the X, Y & Z axes move
simultaneously, while the
remaining two axes are indexed into position and
do not move during that segment of the machining
program. In 3 + 2 machining the NC program rotates
one or two rotary axes into position and locks them
in place while the X, Y & Z axes perform the cutting
necessary to achieve the desired geometry. Typical
applications for 3 + 2 machining include aerospace
manifolds, and multi-sided and compound angle holes.
above: airframe structures
above: airframe
structures
above: compound angle
holes
above: head/table
below: table/table
left: head/head
below: multi-sided parts
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DEMYSTIFYING 5-AXIS MACHINERY
3.0
PROGRAMMING 5-AXIS MACHINES
Manufacturers new to 5-axis machining sometimes
express concerns about the complexity of program-
ming and how difficult it may be for their machine
operators to learn. They also worry about costly crash-
es if the programming is not performed correctly.
Programming Facts
It is true that programming simultaneous 5-axis
machining is more complicated than programming
3-axis machining due to the greater flexibility in tool
path options 5-axis machining offers. However, this
isnt as daunting as it may seem. With the proper train-
ing, an operator with solid programming experience
can learn to program a 5-axis machine.
Most users of 5-axis machines use CAM software
for programming. Used with a high-quality machine,
operating system, spindle and rotary table, a good
CAM system helps insure optimum cycle time, excel-
lent part finish and overall quality. The most efficient
way to approach a part for 5-axis machining is to
break down the processes into 3+2, 4+1 and then
5-axis simultaneous toolpaths. All 5-axis machines are
most rigid when the rotary axes are locked in place,
which allows for Maximum Metal Removal (MMR).
The Okuma 5-axis machines sold and supported by
Gosiger work with all CAM systems, including industry
leaders Mastercam and Esprit.
Collision Avoidance
Crashes can be costly, both in terms of damage to
parts and equipment, and, of course, lost produc-
tion time. Obviously, with five axes in motion, the
opportunity for such incidents increases. The good
news is that 5-axis machines equipped with Okumas
Collision Avoidance System (CAS) take the worry out
of machine crashes, and significantly reduce set-up
time. By entering 3-D model data for the workpiece,
tool, chuck, fixture, headstock, turret and tailstock into
the THINC-OSP controller, machine operators can
view a real-time simulation just ahead of the actual
machine movements. This allows them to check for
any interference or possibility of collision, and imme-
diately stop the machines movement prior to a crash.
During automatic operations, the controller reads
the machining program before beginning an opera-
tion and checks axial travel paths for interference
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DEMYSTIFYING 5-AXIS MACHINERY
4.0
while considering programmed zero-point and tool
compensation values. If it detects interference, the
system temporarily stops axial travel before a colli-
sion occurs. In manual mode, operators can rely on
Okumas proprietary Hairbreadth Stop capability to
avoid any collisions while setting up the machine.
DOES 5-AXIS MACHINING MAKE SENSE FOR
YOUR OPERATION?
Although less than 5% of machined parts require
5-axis simultaneous machining, over 60% of parts
are machined on 5 sides, which means they are all
excellent candidates for 5-axis machining, or what
Gosiger and Okuma refer to as Universal Machining.
Were all looking for ways to make parts and products
faster and better at a lower cost, and 5-axis machin-
ing of multi-sided parts does just that. The result is
improved productivity and profitability. So here are a
number of reasons why Universal Machining with a
5-axis machine is a sound financial decision:
1. Reduced Operator Time Per Part: Using 3-axis
CNC machines for multi-sided parts typically re-
quires considerable operator time to move the
part from one machine to another, and to set up
the parts in between machining cycles. Moreover,
each time a worker touches a part, it adds more
cost to the finished product. These are expenses,
not investments, because they add no value. They
simply drive up the final product cost, reduce profit
margins and make you less competitive. With true
5-axis capability, on the other hand, you can usu-
ally completely machine a part in one cycle with
little or no costly operator intervention.
2. Fewer Costly Fixtures & Tools: Because you are
machining in one operation with all five axes ac-
tively engaged in the cutting process, you typically
eliminate many tombstone, special, top tooling and
rotating tooling fixtures. That, alone, can save thou-
sands of dollars. Moreover, using fewer fixtures
reduces the potential for part tolerance stack-up
errors, and 5-axis machining requires fewer special
tools and tool extensions, and increases tool life.
above: fewer special tools
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DEMYSTIFYING 5-AXIS MACHINERY
5.0
3. Greater Flexibility & Increased Spindle Usage:
As your customers requirements change, a ver-
satile 5-axis CNC machining center enables you
to quickly set up and make new parts, whether
simple or complex in nature. With this kind of
flexibility, the 5-axis machine spends more time
making complete parts, rather than waiting to
perform only a fraction of a machining opera-
tion. This capability also makes you better able
to service customers with Just In Time (JIT) and
KANBAN programs.
4. Reduced Floor Space Requirements: One 5-axis
CNC machining center can perform the work of
multiple, dedicated machines. For example, some
5-axis machine users have eliminated one or more
lathes, vertical machining centers and horizon-
tal machining centers. Think of the floor space
you can put to better use or eliminate entirely
by replacing 4 or more machines with one 5-axis
machining center.
5. Lower Inventory Investment: To meet your cus-
tomers JIT demands, many manufacturers using
3-axis machining for multisided parts find they
must carry a significant inventory of partially
machined parts. This work-in-process (WIP) ties
up capital and adds to overhead. Because 5-axis
machines produce finished or near finished parts
in a single cycle and in a shorter time, you can
reduce WIP and relieve the strain on your cash
reserves or lines of credit.
6. Makes You More Competitive: Even if you dont
currently need 5-axis simultaneous machining,
the ability to handle complex parts allows you
to bid jobs in industries that may not have been
open to you previously. For example, workpieces
requiring compound angles or part features such
as cutting a constant radius along a tapered wall
can only be done on a true 5-axis CNC machine.
Additionally, the reduced cycle time means you can
more quickly turn around orders for a customer
who might otherwise go elsewhere.
above: high effciency tooling
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DEMYSTIFYING 5-AXIS MACHINERY
6.0
JUSTIFYING THE COST OF INVESTMENT
As conscientious business people, we need to translate
the many advantages listed above into financial terms.
Although we cant quantify the impact of every one of
these factors, we can offer the following illustration
comparing machining a six-sided prismatic part on
standard, 3-axis machines and on a 5-axis machining
center. Depending on the print feature requirements,
processing on a 3-axis machine requires four to six
operations, versus one or two operations on a 5-axis
machine.
Existing Manufacturer Process: 3-Axis Machining
Center, 8K RPM, 9 operations
Equipment QTY
Cost
Each
Extended
Cost
Vertical Machining
Center
6 $150,000 $900,000
Fixtures 6 $3,500 $21,000
Dedicated Tooling
Spindle
20 $400 $8,000
Dedicated Employees 6 $80,000 $480,000
Total Cost $1,409,000
5-Axis Process: Okuma MU-400VA, 5-Axis Machining
Center, 8K RPM, 2 operations
Equipment QTY
Cost
Each
Extended
Cost
Vertical Machining
Center
2 $450,000 $900,000
Fixtures 2 $5,000 $10,000
Dedicated Tooling
Spindle
5 $400 $2,000
Shared Employees 2 $80,000 $160,000
Total Cost $1,072,000
TOTAL SAVINGS: $337,000
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DEMYSTIFYING 5-AXIS MACHINERY
7.0
JUSTIFYING THE COST OF INVESTMENT (CONT.)
Clearly, there are significant, immediate financial
rewards inherent in 5-axis machining, along with
improved product quality, quicker turnaround for
customers, improved throughput and spindle utiliza-
tion, and reduced floor space requirements.
*NOTE: The numbers used in the above examples are
generalizations for illustration purposes only. Individual
results will vary depending on the actual costs of the
items included. A Gosiger 5-axis machining specialist
using your specific information can help you determine
the potential savings for your operation.
WHICH 5-AXIS MACHINE IS RIGHT FOR YOU?
If you decide that investing in a 5-axis machining center
is the right move for your operation, the next step is
to determine the kind of system that best fits your
unique requirements. Thats where the applications
experts at Gosiger can help. As a nationally respected
machine tool provider with an unequalled technical
service and support staff, we can help you analyze your
process and recommend the Okuma 5-axis machine
that best suits your needs.
Standard Part Processing
HMC $425,000
Tombstone (special) $40,000
Top tooling (fxture) $10,000
Spindle tooling - dedicated $30,000
Employee - dedicated $125,000
Total Cost $630,000
5-Axis / Universal Part Processing
HMC $425,000
Tombstone (special) $3,000
Top tooling (fxture) $3,000
Spindle tooling - multi-use $30,000
Employee - shared $30,000
Total Cost $491,000
CAPITAL COST REDUCTION: 28.3%
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DEMYSTIFYING 5-AXIS MACHINERY
8.0
Vertical Mill
MU-400VA
MU-500VA
MU-6300VA NEW MODEL!
MU-10000H (table/table
A/C) NEW MODEL!
Vertical Mill with Turning
MILLAC 330TU NEW MODEL!
MU-500VAL
MU-6300VAL (table/table A/C)
NEW MODEL
Horizontal Mill
VH-800
VH-1000 (table/head B/A)
Double Column Mill*
MCRB-III (head/head
C/A)

Horizontal Multifunction Lathe
Multus
Macturn (spindle/axis head
C/B)
Vertical Multifunction Lathe
VTM80-YB
VTM1200-YB NEW MODEL!
VTM200-YB (C/A)
Millac 8535X PF
For complete specifications on all Okuma 5-axis ma-
chines, contact Gosiger or visit www.Gosiger.com
Note: Work heads on select Okuma Double Column
machining centers are changeable. Vertical, fixed angle
or 5 axis simultaneous C/B heads are available. This
allows for maximum rigidity and accuracy to meet
your precise requirements.
Gosiger would like to thank Okuma 5-Axis Product
Specialist, Kyle Klaver, for his invaluable contribu-
tions to this paper.
THE COMPREHENSIVE OKUMA LINE OF UNIVERSAL
MACHINING SYSTEMS INCLUDES: