5-Axis Machines Are Expensive: The Myth About High Cost And ROI

At SIMUL we aim to break the price barrier that often limits the choices of many. Our machines offer a compelling alternative to expensive options or settling for used or lower-quality equipment. We prioritize delivering value without sacrificing quality.

To be clear, 5-axis machines are not for all shops, but you do not have to be machining complex parts like impellers and blisks to realize a positive ROI with a 5-axis machine. Five-axis capabilities allow you to run more efficiently by significantly reducing downtime due to the ability to use less complicated fixturing, reduced number of setups per part and potentially significantly less less tool changes per part. These machines can also open new possibilities by allowing shop owners to quote on more complex and higher margin jobs.

The Transition to 5-Axis: Redefining Expertise

Experienced machinists may fear that embracing 5-axis machining will diminish their expertise and disrupt their established status on the shop floor. However, learning to operate a 5-axis machine is not as daunting as it may appear. As the popularity of 5-axis machines grows, the technology becomes more user-friendly and accommodates a wider range of skill levels. This makes it easier for both seasoned and novice machinists to acquire proficiency in 5-axis machining. From programming to dashboard functionality, processes are becoming less labor-intensive and more standardized, allowing machinists to adapt to 5-axis machines quickly and confidently.

I’m Going To Crash The Machine: Mitigating 5-Axis Collision Risks

With more moving parts and more cutting angles compared to a 3-axis machine, operators will have more variables to keep an eye on as they are machining parts. If, however, the post processor is accurate and tested, machinists can run tests during programming to see if there is the threat of collisions during the machining process on that specific setup.

There are many readily available path verification software options from CAM (computer aided machining) and other software providers. Also, depending on your machine tool, it may be equipped with software that gives you the ability to eliminate potential collisions prior to machining your parts, which will not only keep your shop running smoothly, but it will preserve the life of your 5-axis machine. By utilizing these tools and technologies, operators can ensure smooth operations, prevent costly collisions, and prolong the lifespan of their 5-axis machines.

Demystifying Programming Complexity

The perception that programming 5-axis machines is overwhelmingly complex often discourages manufacturers from exploring this technology. While simultaneous 5-axis cutting and intricate part geometries may be the first things that come to mind, the reality is that programming for 5-axis machining is often simpler than anticipated. 

Many projects suitable for 5-axis machining do not require simultaneous 5-axis cutting, and the programming approach is similar to that of other machines in your shop. Moreover, for most 5-axis projects, the programming is done off the shop floor by dedicated programmers. Operators are merely responsible for loading and executing the pre-programmed instructions. They do not need an in-depth understanding of vectors, simultaneous 5-axis versus 3+2 axis machining, or tramming. This streamlined process reduces the programming burden on the shop floor.

Addressing Operator Apprehensions

Many machinists harbor reservations about operating 5-axis machines, primarily due to the historical learning curve associated with this technology. Fear of complex setups and the potential for damaging expensive machinery can hinder the adoption of 5-axis machining. However, training and operator support have evolved to make the transition much easier. 

Modern 5-axis machines provide guided assistance throughout the machining process, from setup to part change. Furthermore, collision avoidance technology helps mitigate risks. These advancements, coupled with simplified controls, make it more accessible for operators with machining experience to adapt to 5-axis machines.