Four-axis CNC machining guide

Unlocking complex geometry: an in-depth guide to four-axis CNC machining

For engineers, designers and manufacturers, pushing some of the boundaries of complexity and efficiency, CNC machining is an essential technology. While the three-axis machine is the industry’s home field of work, the introduction of a fourth axis can result in a significant leap in unlocking capabilities. This guide delves into four-axis CNC machining: Exploring its working principle, its transformative advantages, key applications, factors to consider, and how to combat other technologies such as 3-axis and 5-axis machining.

Beyond the Basics: How the Fourth Axis Innovate CNC

The standard three-axis CNC machining center moves the cutting tool in the form of three linear paths: X (left and right), Y (front and back) and Z (up and down). This is perfect for machining functions on the top and sides of the workpiece. Four-axis CNC machining increases rotational motionusually around the X-axis – is specified as A-axis.

• mechanism: The fourth axis is usually used Rotating table or Indexer Integrate on the machine’s workbench. The workpiece is securely mounted on the rotating device. Processing period:

  • The cutting tool can move along X, Y, and Z as usual.
  • Rotating table Rotating the workpiece (A axis) at the same time (4 axes at the same time) or in sequence (indexed 4 axes), presenting different faces or angular positions to the cutting tool.

• At the same time with the 4 axes of the index:

  • Index 4 axes: The machine stops cutting, rotates the part to a precise new angular position (such as 90 degrees), locks firmly, and then resumes machining. This is very effective for adding functionality to multiple sides of multiple cube parts in a single setup.
  • 4 axes at the same time: The machine constantly adjusts the tool position (X, Y, Z) although The rotation axis (A) rotates continuously. This makes the real Contours of complex surfacescylindrical machining, spiral features and complex profiles such as cam lobes.

• Key Components: The system relies on precise servo motors, high-speed spindles, rotary tables for excellent accuracy and repeatability, as well as complex CNC controllers capable of synchronizing linear and rotary motion.

Why choose four-axis? Attraction over 3 axes

The benefits of merging the fourth axis are great:

1. Sharp reduction in settings: The holy grail of manufacturing efficiency. Four-axis allows machining functions on multiple faces (usually 4 sides) or on complex angles In a fixture. Eliminate parts deletion, redefine and reorganize to cut cycle time, reduce labor costs and is crucial Improve parts accuracy By minimizing cumulative errors from multiple settings.
2. Enhanced complex geometry: Four-axis machining is excellent where the three-axis reaches its limit. Smoothly machined composite profiles, cylindrical features (threads, slots, gear teeth), spiral paths (flutes on rig/faucets), and asymmetrical parts become feasible and effective. This greatly expands design freedom.
3. Improved finish: Simultaneous 4-axis machining allows cutting tools to maintain optimal orientation (such as side milling or contour) on complex paths, with superior surface quality compared to typically relying on many small stepping or non-optimal tool interactions.
4. Improve accuracy and repeatability: Reducing setup changes are directly related to higher overall part accuracy. When completed in the same setting, the functions processed on different surfaces maintain precise spatial relationships. Modern rotating tables provide excellent positioning repeatability.
5. Reduced fixed complexity: Designing and manufacturing complex fixtures to hold parts at multiple angles becomes less critical. The rotary meter itself acts as a multifunctional positioning device.
6. Cost-effective: While machine and programming investments may be higher than 3 axes, setup, labor, fixed demand, and dramatic reductions in waste caused by misalignment often lead to substantial overall cost savings, especially for low to medium volume generation.

Four-axis machining position: different applications

Its unique features make 4-axis machining essential in many departments:

• aerospace: Impeller, turbine blades (early forms of flicker and flash), engine components, structural brackets with complex angles.
• car: Cylinder head, transmission housing, drive shaft assembly, wheels, suspension parts, custom aftermarket components.
• Medical equipment: Implants (customized and standard), surgical instrument housing, prosthesis requiring complex contours, biocompatible tools.
• vitality: Valve body, pump impeller and housing, compressor assembly, generator parts.
• Industrial Machinery: Cam, custom gears, robot arms, complex housing, drill body.
• consumer goods: Sculpture elements, custom furniture components, ergonomic handles, intricate molds/molds, specialized tools.

Is the four-axis suitable for your project? Main considerations

Choosing between 3, 4 or 5 axes requires careful evaluation:

1. Partial geometry: Do prismatic (Boxy) parts require the function of different faces? Need to perform complex contours on the cylinder? Do you need spiral function? If so, then 4-axis might be excellent. For highly organic, free-shaped, real 5-axis that require undercut from multiple directions, it may be better.
2. Volume and Complexity: For prototypes or very simple parts, 3 axes may be enough. When complexity increases and volume proves to decrease the set time is reasonable, the 4-axis shows its intensity.
3. Accuracy required: Projects that require high precision or seamless transitions between machining surfaces often benefit from fewer settings provided by 4-axis or 5-axis machines.
4. Budget: Four-axis machines are usually cheaper than 5-axis, but require a higher investment than 3-axis. Trade-offs are achieved by saving operating costs (setup, labor). For complex simultaneous paths, programming complexity and cost also increase slightly.
5. supplier: Working with a store, not only have 4-axis function, but with important Programming and optimization expertise It is crucial. Abuse of ability can negate its advantages.

Utilize expertise: Working with Greatlime

While this guide focuses on four-axis technology, it meets its comprehensive potential needs, enabling complex equipment and deep expertise. The company likes it Great Take advantage of their advanced features and master them Five-axis CNC machiningdelivering excellent quad-axis results.

As a professional five-axis CNC machining manufacturer, Gregmigh brings:

• Advanced Technology: The power of complex geometry is ensured with high-precision quad-axis machinery and its sharp five-axis equipment.
• In-depth process knowledge: Expert programmers optimize four-axis strategy (whether it is multilateral machining of simultaneous contours or indexes) – maximizing efficiency, tool life and surface quality.
• Material versatility: Proven experience can process a wide range of metals, including challenging materials such as hardened steel, titanium and gonik alloys, which are often essential in demanding four-axis applications.
• End-to-end support: A comprehensive service, including one-stop post-processing and finishing, ensures that parts are fully processed and ready for assembly or use.
• Agility and customization: Ability to handle rapid turnaround of prototype and low-capacity production and customized precise machining requirements.

For projects requiring more than three-axis machining can offer, but not necessarily requiring the full complexity of five-axis (usually expense) at the same time, work with experts like Greatlime to leverage its quad-axis functionality to ensure optimised manufacturing results of extraordinary value.

Conclusion: The strategic edge of quad-axis machining

There is a key gap in the modern manufacturing industry with four-axis CNC machining bridges. It provides a powerful combination of enhanced complexity handling, large amounts of time and cost through reduced settings, improved accuracy and excellent surface finishes for specific part geometry. While the 3-axis is still the basis and the 5-axis can handle the most organic shapes, the quad-axis is an optimized solution for prismatic parts that require multiple faces, requiring multiple faces or complex cylindrical/spiral features. Technically and economically, understanding their capabilities and limitations is key to making informed manufacturing decisions. Whether developing prototypes or expanding production, combined with four-axis machining supported by expert partners like Greatlight, effectively and reliably provides clear strategic advantages in producing high-precision, geometric complex parts.

Frequently Asked Questions about Four-axis CNC Machining (FAQ)

Q1: What are the main differences between 4-axis and 5-axis CNC machining?

Answer: The basic difference lies in the number and type of simultaneous movements. one 4 axes The machine has three linear axes (X, Y, Z), and one Rotating axis (usually the A axis rotates around X). It allows machining functions on multiple sides or complex surrounding contours Mainly In a cylindrical shape. one 5 axes The machine has been added second The rotation axis (for example, the b-axis rotated around y or around z) enables the tool to approach the workpiece simultaneously from any direction at the same time, which is essential for machining complex organic shapes and deep cavity.

Q2: Is 4-axis machining more expensive than 3-axis machining?

Answer: General Yesthe increase in costs is mainly driven by the following methods:

• Higher machine acquisition costs.
• Potentially higher programming complexity/cost, especially simultaneous motion.
• More complex rotating tools and fixing.
  but, The operating cost per part may be significantly lower than 3 axes Due to the reduced setup, faster cycle times, lower labor per part, and a smaller fixation, it is suitable for suitable parts. Despite the higher machine speed, overall project costs may be lower.

Question 3: Can 4-axis machining do everything that 5-axis can do?

one: No. Although very powerful, the 4-axis machining performed simultaneously is limited to tool movement coordinated with rotational rotation Single Rotate axis. This performs well on cylindrical parts and spiral paths, but fails to achieve the complex undercutting functionality provided by two simultaneous rotation axes machined by two real 5-axis (e.g., machining a deep bag or deep pocket or a sculptural shape that requires approaching the bottom surface of a sculptural shape from multiple angles).

Question 4: What typical tolerances can be achieved in 4-axis machining?

A: Modern 4-axis machining centers, especially constructions with precision ground rotating tables and rigid structures, can achieve very tight tolerances similar to high-end 3-axis machines, usually in ±0.0005 inches (±0.0127 mm) or higher positional accuracy and surface surface surface depending on part size, material, machine condition, tooling and specific features. The reduction in inherent settings of 4-axis machining is the main factor in ensuring tighter Comprehensive Compared with the generation of multiple settings of 3 axes, partial accuracy.

Q5: What file format do I need to provide 4-axis machining quotes?

A: The most common and favorite format is Native 3D CAD filessuch as step (.STP), IGES (.igs) or native solid working/solidgedge/catia/Inventor model. Although 2D graphs with GD&T are critical to specifying critical dimensions and tolerances, 3D models are critical to generating complex tool paths required for 4-axis machining. Make sure your design clearly indicates any functionality that requires the fourth axis movement. Famous manufacturers (such as Greatlight) can work with you to analyze the design and propose the most effective machining strategies.