Manufacturing 101
Max Out 5-Axis Value with the Right Cutting Tools
Industries such as aerospace, die and mold, automotive, and medical are constantly pushing for faster cycle times and lower production costs. This demand is driving both OEMs and their suppliers to seek innovative manufacturing solutions, resulting in the growing popularity of 5-axis machining. As a result, more machine builders are offering 5-axis platforms to keep up with this industry shift.
Why Choose 5-Axis Machining?
The answer is simple: 5-axis machining has become a fundamental requirement for staying competitive. While you may be able to get creative with your current 3- or 4-axis machines, doing so would likely require multiple setups—cutting some features on one machine and moving to another machine to complete the part. This not only adds setup time but also presents challenges in maintaining tight tolerances when transitioning between machines.
Additionally, if one machine in your workflow creates a bottleneck, you could face significant delays, waiting half a day or more for it to become available. This downtime could prevent you from winning bids, meeting delivery deadlines, and, most importantly, maintaining profitability.
Fortunately, many of these challenges can be minimized or eliminated with 5-axis machining.
The Advantages of 5-Axis Machining
The real benefit of 5-axis machines lies in their ability to handle more complex tasks with fewer setups. By reducing downtime and touchpoints, you increase efficiency and profitability while improving delivery times for your customers.
The formula is straightforward: fewer setups + increased metal removal rates = reduced cycle times and increased profits. This is why many manufacturers are upgrading to 5-axis machines, even before replacing old equipment, to stay competitive and bid more effectively on new parts.
The Challenges of 5-Axis Machining
While 5-axis machines offer many advantages, they do come with their own set of challenges. The additional axes (beyond the standard XYZ) introduce more complexity to programming, requiring operators and programmers to acquire new skills and training.
Another common issue is the reach constraint that wasn’t a concern in 3-axis machining. This often requires entirely new cutting tools and tool holders to avoid collisions and optimize the machining process.
Furthermore, the industries that frequently rely on 5-axis machining often work with exotic and costly materials like stainless steel, titanium, Inconel, and cobalt-chrome. These materials not only come with a higher price tag but also demand greater tooling efficiency to manage wear and tear.
The Solution: Custom Tooling for Maximum Efficiency
This is where GWS steps in. We specialize in creating custom tooling solutions specifically designed for 5-axis machining. With GWS tools, you can fully leverage the enhanced capabilities of your machine and maximize your return on investment.
Our custom tool offerings include:
- Barrel endmills
- Tapered endmills
- Spherical endmills
- Bullnose high-feed endmills
One of the keys to boosting metal removal rates is using the right tool. Standard ball nose tools often lack the necessary cutting edge surface area to get the job done efficiently. Our spherical endmills, combined with the flexibility of 5-axis machining, allow for greater cutting edge engagement, dramatically increasing metal removal rates per pass.
The Power of Customization
Given the complex contours often required by 5-axis parts—such as turbine blades—off-the-shelf tools simply won’t cut it (literally or figuratively). Custom tools, designed specifically for your application, are the key to unlocking the full potential of your 5-axis machine. Whether it’s the tool length, taper, diameter, radius, geometry, substrate, or coatings, GWS custom tools address critical factors like reach, collision avoidance, and tool life.
When it comes to 5-axis machining, GWS is your partner for optimized tooling solutions tailored to your unique needs. Contact us today at sales@gwstoolgroup.com to learn how we can help you achieve greater efficiency and profitability with the right custom tools for your 5-axis applications
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