Five-axis machining has built its reputation in the metal manufacturing world through the many advanced machining strategies that are impossible without the additional rotational axes that set it apart.

​However, many manufacturers have found great benefits in 3+2-axis manufacturing techniques, using the rotational axes to reduce setup time. This approach can provide a firm foundation for highly automated machine cells such as the ones I found at Clippard Manufacturing, a Cincinnati-based valve manufacturer and machine shop.
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Clippard began in the 1930s as a manufacturer of radio parts. Its early claim to fame came during World War II, when it manufactured coils for the Allies’ radio-based proximity fuse — one of the most successful weapon technologies developed for the war. Over subsequent decades, the company pivoted to pneumatic valves for various industries, especially the medical industry. More recently, the company has also begun working as a contract manufacturer of medical parts, putting its experience meeting the exacting standards of the medical industry to further use.

The company’s first foray into heavy automation was in its fleet of 20 Swiss-type lathes, which found success working lights-out. Using this success, Manufacturing Engineer Alex Werdman convinced the company to invest in a five-axis Haas UMC 500 SS with a 16-station pallet changer to perform work that had been done on three-axis mills. The company made this investment with the intention of developing lights-out processes for the machine cell, but getting to that point meant investing in more than just the machine tool.

One of the major draws of a five-axis machine was the ability to dramatically reduce setup time by machining multiple faces of parts in a single setup. According to Werdman, the move to the five-axis Haas made the jump to high-mix medical work much easier. “Being able to reach more faces of the part reduced the setup time for secondary operations by a lot,” he says. “Jobs that took 45 minutes per part on a three-axis were down to 27 minutes.” CNC Programmer Kyle Shearer agrees, saying, “I might touch a part 17 times before and only four times now.” However, this strategy relied on workholding that provided the cutting tool as much access to the part’s faces as possible.

At first, Clippard considered using dovetails, but after a conversation with Jergens representatives and distributors, the company opted for vises with modular jaws. “We thought we would have to use dovetails,” Werdman says, “but the vise has enough grip force and clearance to meet our needs.”
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​And did this work pay off? “The Haas proved that five-axis machines were worth it,” Werdman says. “We could get 50 hours a month on the three-axis mills, and with fiveaxis we get 200-300 hours.”

The success of the Haas spurred Clippard to invest further in five-axis machining with a Matsuura MAM72-35V, intended to both increase the volume of parts the company could produce lights-out and improve the precision of its fiveaxis machining.

The Matsuura came standard with a 32-station pallet changer in a condensed footprint, dramatically increasing the capacity for lights-out machining. Like the Haas, it regularly puts in over 200 hours of machining time, mostly performing 3+2-axis machining. It can also pursue more aggressive machining strategies while maintaining the finish needed, as it can maintain a tolerance of ±0.0005 inches.
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Despite being one of the major benefits of five-axis machining, this kind of dramatic increase in capacity and production speed is often overlooked by machine shops. Not all fiveaxis machines produce near-net shapes or large contours, and shops like Clippard have found great success thanks to careful consideration of the machine cell as a whole.

​“The people in charge needed convincing,” Shearer says, “but once they saw how much more we could get done and how quickly we could do it, they were on board.”

Masa Tool, Inc. is a company founded with the mission of bringing micromachining solutions to industry. 

The Microconic™ work holding system is  a mechanically actuated micro-workholding system for use in high precision, small diameter CNC turning applications.

It's the first and only workholding system for the micro machining industry!
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edited by Bernard Martin

Founded in Hamburg Germany, the Soph Company have focused their efforts on developing and producing magnetic chucks under the BRISC brand name. Brisc Magnetics Co., Ltd was founded in 1998, specializing in designing and manufacturing magnetic work-holding, clamping and lifting equipments. With advanced design, outstanding performance and unsurpassed reliability they fit well in Soph's product mix

Soph's BRISC brand manufactures all kinds of magnetic chucks including permanent magnetic chucks, electromagnetic chucks and electro-permanent magnetic chucks for many work holding applications like grinding, milling, turning, EDM & WEDM.

The goal is to apply their experience and technology into the field of magnetics to provide our customers with the best magnetic solutions available in industry today.

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

by DEREK KORN | Editor-in-Chief, Production Machining Magazine

For some turning applications, chuck jaws or other conventional workholding devices for CNC lathes can cause a part to distort as clamping force is applied. This can be the case for large, thin rings such as the one shown on the left. Those workholding elements can also prevent full access to a part, which might necessitate reclamping for an additional operation.
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The threaded grippers install in the top of a fixture plate and require a through-hole to enable the UV light to pass up and through the gripper to cure the adhesive. For most turning applications, this would be done at a workstation and the fixture plate with bonded part would then be installed on the lathe.
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To do this, the top of each gripper and the areas of the part to be gripped are cleaned with isopropyl alcohol. Adhesive is deposited on the top of each gripper so that the entire gripper face is covered and the gap between the face and underside of the part is filled. The gaps (thus, the thickness of the adhesive) can range from 0.020 to 0.120 inch, depending on part flatness. The part rests on hard stops installed in the fixture plate that are slightly taller than the gripper tops to achieve the proper gap.
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To cure the adhesive, the UV light source’s light guide is inserted into the backside of each gripper and the source is activated. It typically takes 60 to 90 seconds for the UV light to cure the adhesive, bonding the gripper to the part. Once curing is complete for all grippers, the fixturing element with the part can be installed in the machine and machining can be performed.

Once machining is completed, a wrench is used to back off each threaded gripper, shearing the adhesive bond with the part. The residual adhesive can then be peeled off the part and grippers after applying steam, or a hot water soak or spray.

​The number of required grippers is based on the size of the part and its geometry, the company says. Axial holding force depends on gripper size and can range from 250 to 800 pounds. Grippers are made from hardened, corrosion-resistant stainless steel and have a black oxide finish. The adhesive is compatible with most water- and oil-based coolants and cutting fluids. It is said to be able to hold a variety of ferrous and nonferrous metals as well as plastics, ceramics and composite materials.