Any seasoned machinist or manufacturer of distinct components, simple or complex, will agree that CNC milling machines have been nothing short of revolutionary since their inception. Whether it is a simple 3-axis mill or a more advanced 12-axis mill, their impact on manufacturing is hard to argue with. This article breaks down CNC milling machines by the number of axial movements they support, to help machinists and industrial manufacturers scale up production.
CNC Milling Machine Axis Count: At a Glance
Multi-axis milling machines are presently a must-have for small and medium-scale machinists as well as industrial manufacturers. The number of axes endowed in a milling machine essentially determines the machining operations supported and the quality of finished components fabricated.
This table summarizes the distinct CNC milling machines available today, their respective axis count, and their core capabilities.
| CNC Machine Axis Configuration | Core Capability | Part Complexity | Setup Requirements |
| · 3-CNC milling machine | · 3 axial movements, namely X, Y, and Z. | · Ideal for simple parts and components. | · Necessitates multiple setups to execute multi-face machining. |
| · 4-axis CNC milling machine | · Supports 3 linear movements (X, Y, and Z), plus an extra rotary movement (A-axis) | · Ideal for moderately complex parts. | · Minimal repositioning. |
| · 5-axis CNC milling machine | · Operates along the X, Y, Z, A, and C axes. | · Ideal for machining highly complex components. | · Reduced setups. |
| · 6-axis CNC milling machine | · Operates along the A, B, and C axes in addition to the X, Y, and Z axes. | · Perfect for highly complex geometries. | · Requires fewer setups. |
| · 7-axis CNC milling machine | · Supports additional movements, namely X, Y, and Z axis translation, A, B, and C axis rotation, and E-axis rotation. | · Ideal for highly intricate geometries. | · Single setups. |
| · 9-axis CNC milling machine | · Supports multiple coordinated movements, namely, X, Y, Z, A, B, C, E, U, and W-axis motions. | · Specialized for extremely complex geometries and parts. | · Minimal setups. |
| · 12-axis CNC milling machine | · Supports 2 cutting heads, each moving independently along 6 different axes. | · Ideal for the most complex parts and geometries. | · Extremely minimized setups. |
Whilst CNC milling machines may support the same number of movements, it is worth noting that their configuration may differ slightly depending on the manufacturer.
Comparing Machining Capability: 3-Axis, 4-Axis, 5-Axis, 6-Axis, 7-Axis, 9-axis, 12-Axis
· Machining Capability
Compared to older versions of milling machines, it is quite evident that CNC multi-axis mills offer unrivalled machining capability. However, the machining capability of any CNC mill rests solely on the number of axes supported. A 3-axis CNC mill, for instance, offers the least machining capability due to its relatively limited axis count.
The machining capability rises steadily as the number of axes increases, leaving the 12-axis CNC mill as the most capable option. The 4-axis, 5-axis, and 6-axis mills offer moderate machining capabilities, making them ideal for small-scale machining as well as commercial part fabrication.
· Workpiece Accessibility
To accurately fabricate workpieces and impart intricate geometries on them using a CNC milling machine, multiple axes are needed. As such, CNC mills with the most axes, such as the 9-axis and the 12-axis CNC mills, guarantee greater accessibility. This is primarily because a higher axis count simply translates into more paths for the respective milling or cutting tools.
In a 3-axis CNC mill, for instance, the cutter’s path is limited to one direction, given that the mill only supports the X, Y, and Z axes. In CNC milling machines with comparatively more axes, such as the 6-axis, the 7-axis, the 9-axis, and the 12-axis, however, the cutter can move in various directions, ultimately making it possible to fabricate otherwise impossible geometries.
· Setup Capability
Multi-face machining helps reduce machining cycles significantly, and CNC milling machines with multiple axes reduce the need for multiple setups greatly. Machining complex geometries using a 3-axis or a 4-axis CNC typically requires multiple setups due to the limited workpiece accessibility and machining capabilities of these mills.
Milling complex parts using advanced mills with 6,7, 9, or 12 axes, on the other hand, requires minimal setups, consequently promising faster turnaround times and improved production capacity. Furthermore, it reduces the need for additional machinery, ultimately driving down the cost of production for machinists and manufacturers.
· Geometry Capability
12-axis CNC milling machines thrive in workshops and manufacturing facilities specializing in the fabrication of complex parts or components with relatively intricate geometries. This is because they allow extra movements along additional paths, making it possible for operators to make multiple distinct cuts within one machining cycle.
9-axis, 7-axis, and 6-axis CNC mills also promise great geometry capabilities, explaining their continued and consistent use in commercial workshops and industrial manufacturing facilities handling intricate parts.
3-axis mills, in contrast, can only fabricate complex features in multiple setups and cycles. Their limited axial movement limits their machining capability to fabricating simple flat surfaces rather than complex features such as tapers.
· Production Capability
Whilst 3-axis and 4-axis CNC mills guarantee much faster turnaround times compared to manual and semi-automatic milling machines, they cannot match the production capability of 6-axis, 7-axis, 9-axis and 12-axis CNC mills. The latter CNC milling machines are favored by industrial machinists and manufacturers, particularly those fabricating parts with intricate geometries in bulk.
They not only guarantee greater precision, but they also promise fewer and quicker machining cycles. This allows manufacturers to generate more high-quality components in fewer setups, thus lowering their cost of production.
When to Choose:
Whereas CNC milling machines with relatively more axis configurations boast greater machining and production capabilities, there are scenarios where CNC mills with fewer axes reign supreme. The table below summarizes the recommended uses of the distinct CNC milling machines discussed above.
| Axis Configuration for CNC Milling Machine | When to Use the CNC Milling Machine |
| 3-Axis | · Fabricating simple or moderately complex workpieces. |
| 4-Axis | · Machining parts with moderately complex features such as engine mounts. |
| 5-Axis | · Manufacturing complex components in demanding industries such as medical device manufacturing. |
| 6-Axis | · Fabricating complex parts with high tolerance, such as aerospace parts. |
| 7-Axis | · Machining components with complex geometries such as medical implants and turbine blades. |
| 9-Axis | · Fabricating high-precision parts with comparatively detailed geometries such as medical devices and automotive components. |
| 12-Axis | · Manufacturing ultra-complex components with relatively higher tolerances, including complex aerospace parts and medical devices. |
FAQs
Does more CNC axes always mean better machining capability?
Yes. A higher axis count generally translates into more machining opportunities. For instance, the 12-axis CNC milling machine can fabricate any complex part known to man. Meanwhile, the 3-axis CNC mill is limited to fabricating simple components such as flat or cylindrical housings.
Which CNC milling machine capability reduces setups?
Incorporating multi-axis machining not only optimizes production for machinists, but it also minimizes or eliminates the need for numerous setups. It simply makes it possible to impart distinct geometries on a single workpiece simultaneously without necessitating any operator involvement.
What is the difference between 3-axis, 4-axis, and 5-axis CNC milling machines?
3-axis, 4-axis, and 5-axis CNC machines are simply distinguished by their unique axis count and configuration. They are named after their respective axis count, and this simply determines their machining capabilities, with the capabilities increasing as the number of axes increases.
Which CNC milling machine is best for complex geometries?
CNC milling machines with between 6 and 12 axes are generally favored when it comes to fabricating complex geometries that require high precision. The 12-axis CNC mill, in particular, reigns supreme in the production of ultra-complex components and parts, especially medical components and aerospace parts.
How does axis count affect the CNC milling cycle time?
The number of axes in a CNC milling machine generally determines how much time it takes to fabricate a multi-faceted workpiece. Milling machines with more axes allow for simultaneous and multi-part machining, which significantly reduces or even eliminates the need for operators to manually flip the workpieces.
How do you choose the right CNC milling machine axis configuration?
While a higher axis count promises greater machining capability and higher productivity, you must bear in mind that the suitability of a CNC milling machine to a specific role depends on its configuration and the role’s requirements. Other essential factors that come into play include the part’s desired geometry, material type, and production volume.
Final Thoughts
When sourcing CNC milling machines or their respective repair parts for manufacturers and/or machinists, you must be well aware of the distinct axis configurations available. This will help you point your clients towards the befitting CNC machine rather than the outstanding one, ultimately helping them optimize their production.
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