Industrial Six Axis CNC Machining Solutions
The Power of 6-Axis Machining in Heavy Industries
Modern manufacturing faces growing demands: complex part geometries, tighter tolerances, and harder materials. Six axis cnc technology meets these challenges head-on with unparalleled flexibility.
According to SME’s 2023 report, 6-axis machines reduce setup times by 58% compared to 4-axis systems for large industrial components. The extra rotational axes enable true simultaneous machining.
5-Axis vs. 6-Axis: Critical Differences
| Capability | 5-Axis CNC | Six Axis CNC |
|---|---|---|
| Tool Approach Angles | Limited to 3 rotary directions | Full spherical movement |
| Large Part Machining | Requires repositioning | Single setup possible |
| Surface Finish Quality | RA 1.6μm typical | RA 0.4μm achievable |
However, the real advantage isn’t just about axes count. It’s about smarter toolpath optimization.
Step-by-Step: Machining Industrial Valve Housings
- Secure 316L stainless steel blank using hydraulic vise (15,000 psi clamping force)
- Program using CAM software with 6-axis postprocessor (we favor Mastercam Multi-Axis)
- Verify tool clearance in simulation (watch for C-axis collisions)
- Rough machine with 12mm carbide endmill (18,000 RPM, 0.2mm/tooth)
- Finish internal channels using 6-axis contouring (4mm ballnose cutter)
Common Industrial Mistakes
⚠ Attention: These errors plague 60% of first-time 6-axis users:
- Using outdated tool libraries (causes 23% longer cycle times)
- Neglecting thermal growth compensation (0.015mm drift/°C in steel)
- Overlooking chip evacuation (leads to 40% tool life reduction)
Case Study: Mining Equipment Gears
Our team faced a nightmare scenario last year. A client’s 5-axis machine couldn’t handle the undercuts in 4340 hardened steel gears. Switching to industrial six axis cnc reduced machining time from 9 hours to 4.2 hours per gear.
The game-changer? The machine’s W-axis (linear plus rotary) allowed us to attack gear teeth from optimal angles without repositioning.
Material-Specific Strategies
Industrial applications demand smart approaches:
- Titanium: Max 50m/min cutting speed, high-pressure coolant
- Inconel: Peck drilling required, radial engagement <35%
- Cast Iron: Dry machining possible, but needs air blast
Interestingly, tool selection matters more than raw machine power for these materials.
Implementation Checklist
✓ Verify machine rigidity (≥25 N/μm for steel machining)
✓ Calibrate rotary axes bi-weekly (0.001° accuracy needed)
✓ Implement tool life monitoring (sensors add 15% productivity)
✓ Train programmers on 6-axis kinematics (completely different mindset)
✓ Start with 20% reduced feeds/speeds for new jobs
Frequently Asked Questions
Q: What industries benefit most from industrial six axis cnc machines?
A: Aerospace, energy, and heavy equipment see the biggest ROI due to complex part geometries.
Q: How to choose between 5-axis and 6-axis cnc milling machines?
A: 6-axis excels when you need undercut access or minimal repositioning – common in turbine parts.
Q: What maintenance does a six axis cnc router require?
A: Weekly way lube checks, monthly ballbar tests, and 6-month full alignment calibration.
