Jack Rushlander from Jergens workholding talks about how advancements in 5 Axis CNC machining technology has changed dramatically in the past 20 years. Dynamic Work Offsets and other capabilities have made workholding easier but also given shops even more opportunities to to improve process and reduce cycle time.

5-axis machining is a game-changer in modern manufacturing, allowing for the creation of complex, precise parts with unparalleled efficiency. By enabling simultaneous movement along five axes, this technology significantly reduces the need for multiple setups, resulting in improved accuracy and faster production cycles. However, while its benefits are transformative, the challenges and considerations associated with 5-axis machining are equally significant.
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One of the most striking advantages of 5-axis machining is its ability to streamline operations. Complex geometries that would traditionally require multiple setups can now be completed in a single run, reducing production time and minimizing the chance of errors. This capability not only enhances precision but also eliminates the need for extensive fixturing and repositioning, leading to higher-quality finishes.

Despite these advantages, adopting 5-axis machining is not without its hurdles. The machines are more complex and expensive than their 3-axis counterparts, requiring substantial investment in both equipment and training. Programming 5-axis operations is also more intricate, demanding advanced software and experienced operators who understand the nuances of tool paths and machine kinematics.

Success in 5-axis machining begins with thorough preparation. Selecting the right tools, understanding the machine's capabilities, and ensuring proper workholding are all critical. Matching the machine’s specifications—such as spindle speed, torque, and material handling capabilities—to the project requirements is equally essential.

Accurate part drawings and the right choice of raw materials lay the foundation for a successful operation. Clear, detailed drawings provide machinists with a reliable guide, while high-quality materials ensure both machining efficiency and final product performance. Tools like dovetail fixtures are particularly valuable for securing workpieces during machining, especially for intricate parts requiring multiple angles.

To maximize efficiency, leveraging tools like SolidWorks to define the machine's work envelope can help visualize part orientation and motion. This approach allows operators to identify potential collisions and optimize tool paths before production begins, saving time and resources.

Collaboration plays a crucial role in 5-axis machining. Consulting with machinists during the planning and programming phases can reveal practical insights and preempt potential issues. Troubleshooting is another vital aspect, addressing challenges such as tool deflection, chatter, and thermal expansion to maintain quality. Engaging additional perspectives—whether from colleagues or external experts—can also lead to valuable refinements in the process.

Lastly, clear and comprehensive communication with CNC programmers ensures that tool paths and machining strategies align with the project's goals. Providing detailed specifications, including geometry, materials, and tooling requirements, is essential for effective programming.

In conclusion, while this article covers key points about 5-axis machining, there’s so much more to learn about the process and its practical applications. For a detailed exploration of this technology, watch the full video below and see how Galactic Widget Company tackles the workholding of a Thingamajig and discover insights that can take your machining expertise to the next level.

• 00:00 - 01:35 Introduction
• 01:35 - 03:50 The Pros of 5-Axis
• 03:50 - 06:20 The Cons of 5-Axis
• 06:30 - 09:36 Process Essentials
• 09:39 - 11:53 The Machine
• 11:55 - 15:40 Part Drawing & Raw Material
• 15:50 - 19:45 When to Use a Dovetail
• 19:46 - 21:35 Start to Finish Operation in Drawings
• 21:36 - 30:38 Work Envelope in Solidworks
• 31:24 - 33:58 Analyze With Your Machinists
• 35:30 - 37:08 Troubleshooting
• 37:18 - 37:56 Getting Other Eyes on Your Project
• 38:00 - 39:40 The Process of Sending Project to Your Programmer
• 39:45 - 49:36 Questions

compiled & edited by Bernard Martin

As more and more of our customers are using Martindale Gaylee Circular saws we put together this guide to the commonly asked questions such as "Is there a rule-of-thumb for the number of teeth?" or "How much side clearance should I have?" Here we cover a lot of the fundamentals of selecting the right circular saw blade configuration, some tips, tricks, and troubleshooting for when things go wrong. 

​These are general cutting speed recommendations for circular saws used in metalcutting from Martindale/Gaylee. The may vary from application to application but are basically some general suggestions starting parameters when using high speed or carbide saws. 

• HSS Saws: .002”-.006”  (IPT-inch. per tooth / CLPT-chip load per tooth)
• Carbide Saws: .0002”-.0015”  (IPT -inch. per tooth / CLPT - chip load per tooth)

This is a conservative recommendation as a starting point for feed rates, and may vary depending on material being cut and cutting speed (SFPM).

Generally speaking, deep cuts and soft material require fewer teeth for chip clearance and stronger teeth (landed).

Thin material requires more teeth, but keep-in-mind that at least 2 teeth on the blade need to be engaged in cut. Hard materials and narrow slots (under .025”) likewise require more teeth.

Hard Materials require more teeth, and  give a smoother cut,  but at a much lower production rate.  ​

Alternately beveled teeth keep chips from sticking in the cut and in the tooth gullets.

And Remember that there should be at least 2 teeth engaged in the cut at all times.

RAKE ANGLES
​Just as in an end mill or a band saw blade, a rake angle is the term used to describe the direction of the blade’s teeth, as referenced from the rotation and central axis of a saw blade. If you imagine a line going from the exact center of the blade to each tooth, having the front of the tooth directly on that line would be a zero degree rake angle. The rake angle of the blade is described in comparison to that imaginary line.

A positive rake angle meana that the teeth are angled more towards the angle of rotation, while a negative rake angle would mean that they are angled backwards, away from the direction of rotation. Generally speaking, the preferred rake angle is:

• 5° to 10° positive for other soft materials.
• 5° negative for yellow brass
• On center for steel.

SIDE CLEARANCE (Tangential Clearance Angle)
This is also known as dish or hollow grind.  You measure down the side of the tip and the difference it is the difference between front and back.  As you cut, material it gets compressed and springs back after the cutting edge passes.

​A steep side clearance angle gives plenty of room for the material to expand and prevents thermal expansion of the base material.  Keep in mint that a very flat side clearance angle can provide a smoother cut in some materials.  For stainless steel and tenacious metals such as copper, zinc, tin or lead an increase in the side clearance is desirable as these materials tend to "spring back" (thermal expansion) on the blade.