CNC Milling Services

3 Axis Machining

Three-axis machining is a method of CNC (Computer Numerically Controlled) machining that utilizes a cutting tool to remove material from a workpiece along three different axes simultaneously. This process allows for the creation of complex shapes and surfaces by moving the cutting tool in three dimensions: the X-axis (left and right), the Y-axis (forward and backward), and the Z-axis (up and down).

In a three-axis CNC milling machine, the workpiece remains stationary on the machine bed while the cutting tool moves. The movement along each of the three axes enables the machining of parts with various geometries, from simple flat surfaces and holes to more complex features like slots, pockets, and even contoured surfaces.

Three-axis machining is widely appreciated for its versatility and efficiency in producing a wide range of parts with relatively simple geometries.

4 Axis Machining

Four-axis machining expands upon the capabilities of three-axis machining by introducing an additional axis of rotation, typically referred to as the A-axis. This axis allows the workpiece to be rotated around the X-axis, enabling the cutting tool to access the workpiece from various angles without the need for repositioning. The four axes in four-axis machining include the traditional X (left to right), Y (front to back), and Z (up and down) axes, with the addition of the A-axis for rotational movement.

The inclusion of the fourth axis enhances the machine’s ability to create complex parts with intricate geometries, undercuts, and non-orthogonal features in a single setup. This reduces the need for multiple setups and repositioning of the workpiece, thus increasing precision and reducing production times and costs.

Four-axis machining is particularly beneficial for the production of cylindrical or spherical parts that require features along their surfaces, such as camshafts, gears, and aerospace components.

5 Axis Machining

Five-axis machining represents the pinnacle of CNC machining capabilities, incorporating movement across five different axes simultaneously. In addition to the traditional X, Y, and Z linear axes found in three-axis machining, five-axis machining introduces two additional rotational axes. This allows the cutting tool or the workpiece to approach the workpiece from almost any angle, enabling the machining of extremely complex geometries with high precision in a single setup.

Five-axis machining significantly reduces setup time and the need for multiple setups and fixtures, as the additional axes allow for complete or near-complete part machining in a single clamping. This not only speeds up production but also reduces the chance of errors associated with repositioning the workpiece. Furthermore, the ability to position the tool at optimal angles improves surface finishes, allows for the use of shorter cutting tools (which can reduce vibration and increase tool lifespan), and can result in faster material removal rates.

CNC Milling Process

The process begins with the creation of a CAD (Computer-Aided Design) model, which is then converted into a CNC program using CAM (Computer-Aided Manufacturing) software. This program contains detailed instructions for the CNC machine, including the movement of the cutting tool along the X, Y, and Z axes, the speed of the cut, and the depth of the material to be removed. CNC milling machines operate with a rotating cylindrical cutting tool that moves along multiple axes, allowing for the machining of complex shapes and features.

During the milling process, the workpiece is securely fixed to the machine’s bed or a work holding device, ensuring stability while the cutting tool removes material. The cutting tool can be changed to match the specific requirements of the task, ranging from flat-ended mills for rough cuts to ball-ended mills for finishing surfaces with intricate details. The machine selects and changes tools automatically from its tool magazine, based on the programming instructions, allowing for a seamless transition between different phases of the milling process.

Precision and Complexity

One of the most significant advantages of CNC milling is its ability to produce parts with high precision and complex geometries. This precision is crucial in industries where even the slightest deviation can lead to significant issues.

Efficiency and Speed

CNC milling machines operate with remarkable speed and efficiency, significantly reducing production time. This efficiency is vital for meeting tight deadlines and managing higher volume orders.

Flexibility and Versatility

The flexibility of CNC milling lies in its ability to handle various materials and part geometries. This versatility makes it an ideal choice for custom and standard parts alike.

We have delivered successful CNC milling projects across various industries.

• Aerospace
• Forensics
• Gas & Fluid Control
• Industrial Laser
• Medical Equipment
• Motorsport
• Optical
• Scientific Instruments
• Specialist Engineering