diy 5th axis cnc rotary table factory

So I thought, OK, I have to use a trunnion. Then I thought, why build a 3D printer (prior years project) if you are only to use it for fancy stuff. I have to 3D print something really useful: a trunnion table!

The belts though, you can not avoid, you have to buy them. I tried printing some ninjaflex material but it is not suitable for this application, you need the belts to be really stiff in terms of tension to increase the machine"s accuracy.

If you’d asked me up until very recently whether 5 axis was practical for the CNC DIY’ers and Makers, I would’ve said “No!” without hesitation.  Not only is the hardware complex, but 5 Axis CAM was expensive.  Much of this has now changed fairly recently.  Yes, the hardware is complex and most 5 Axis CAM is still expensive, but there are an increasing number of proof points that is is possible to have a go at 5 axis CNC for the hobbyist.  Let’s have a look at recent developments in this area, but first:

Given that 5 Axis is not at all easy or common, even for Pros, why would a hobbyist want 5 axis?  Sure, there’s always the desire to push the envelope, to do something the mainstream hasn’t done yet.  That’s primal Maker juice at its best, and we’ll trot out this popular 5-axis video just to get those juices flowing:

But there are sound practical reasons to want to do 5 Axis as well.  We’ve written about the advantages of 5 Axis CNC before, but a quick recap here is in order.  Here are the most important bits:

– Fewer Setups:  When you can get at nearly every face of the part except for the very bottom, you have fewer setups needed.  This is especially helpful for the hobbyist who may only be trying to make a one-off part.  No need for complex fixturing and lots of setups with 5 axis giving the cutter better access.

– Machine Parts Not Otherwise Possible:  Let’s face it: something like the helmet shown in the video wouldn’t even be possible without 5 Axis CNC.  Many parts that require a lot of undercutting will be much more difficult without 5 Axis CNC.  It isn’t even just a question of something curvy like the helmet.  With 5-axis, a part can be tilted to allow a shorter tool to get down in a pocket, thus allowing for more rigidity and less tendency for the tool to deflect and chatter.  On a lightweight hobby machine, any increase in rigidity is welcome.

With linear rails, a sweet high speed spindle, and trunion table, the Pocket NC looks the part.  It’s even set up as a horizontal mill, which no doubt gives it greater rigidity than might otherwise be the case.  280 backers pledged $355,833 on Kickstarter to help bring this project to life.  The Kickstarter closed just a couple of weeks ago, so it’s way too early to tell much, but this mill looks extremely promising.  Early signs are good as the Kickstarter sold out 3 weeks early and this enabled them to get a head start making parts for the machines:

As mentioned, the Kickstarter sold out.  We’ll have to wait until they’ve delivered all the machines to that crowd to see whether there will be a Pocket NC for the rest of us, as well as what the reaction of the first group of owners may be.  Personally, I’m hoping everyone loves the machine and that it will be available at their target price of $3500.  That would be quite an accomplishment to be able to purchase a high quality 5 axis desktop CNC mill at such a price.

There have been other desktop 5 axis machines shown, even some on Kickstarter, but the Pocket NC is the first one that seemed so polished.  These things are a bit like the 4 minute mile.  Until someone actually ran a 4 minute mile, it seemed impossible.  Once it had happened, quite a few managed to run it not long after.

The main reason I would have said “No” to 5-Axis for hobbyists up until recently was not hardware, it was software. Talented hobbyists have been modifying a 4th axis to turn it into a 4 axis trunion table for quite some time.  Here is one such:

Building a 5-axis mill is hard enough, but programming it is nearly impossible without CAM, and until recently, 5-axis CAM was very expensive.  Before the advent of true 5-axis CAM, about the best that was available were toolkits to help simplify the hand programming, such as CNC-Toolkit.  While extremely useful, such software was still too hard for most people to tackle.  Just visualizing true 5-axis tool paths is nearly impossible for most.

The Fusion 360 Ultimate version includes full simultaneous 5-axis CAM, and is actually approachable for the Hobby-level market for the first time.  Here is a video of the PocketNC showing how they did a duck call in 5-axes:

It’s premature yet to declare that DIY 5-Axis is here for the masses, but I don’t think it’s premature to suggest that it isn’t far away or that it is almost within reach.  Talented hobbyists can get there today, thanks to the availability of suitable software.  The rest who want to be able to buy an off-the-shelf machine that’s ready to make parts will have to wait a little while longer.

The future is bright.  When I first started playing with CNC years ago I used to think it was amazing that a person could own one of these machines.  After all–they helped put men on the moon.  Now there are more an more of them out there.  I have been meeting people accidentally for a while now that are deeply involved, which is a sign of how commonplace it is becoming.  The thing is, we ain’t seen nothing yet, as the saying goes.  Much more to come!

At Hosea Precision, quality comes first - at every stage of the production process. We are dedicated to producing 5 axis and 4 axis rotary tables, which are two of our proudest products. With the high-quality and precision feature, our CNC rotary tables have been sold & widely used in the European market and have an enormously high reputation amongst our customers.

In March 2015 Hosea Precision created the independent brand, to make it a household name for high-quality 4 axis rotary tables from Taiwan. We have been following this strategy with great success: more and more manufacturers across Europe cooperate with us and make use of our 5 axis rotary tables and other rotary tables products. Do not hesitate to contact Hosea for more products detail!

KME CNC Rigid Cast Iron Trunnion Tables are one of the leaders in the industry for accuracy, surface finishes and repeatability.  Allowing you to speed up your cycle times, these tables are ideal for high volume production applications. Powerful and compact trunnion design ensures smooth operation over the entire travel range.

NIKKEN’s world-renowned CNC Rotary Table range provides proven performance, reliability and accuracy benefits for any application or requirement that others simply cannot hope to emulate.

With an extensive range of rotary table sizes, configurations and options available, all fully supported by our extensive global network, you can be sure to find the perfect product to meet any requirement or machine tool.

Single Axis, Twin Axis, Multi-Spindle, Standard Drive, High-Speed Drive, and Direct Drive capabilities are all available from stock. These can be configured and supplied for control directly by the CNC Machine or by integrating our exclusive Alpha 21 and EZ controllers to provide precise positioning and also full Macro B control (Macro B function – Alpha 21 only).

NIKKEN can also provide a complete and expansive range of accessories precisely engineered and customised to suit both the machine tool and the component. These options include a wide variety of chucking solutions, vices, bespoke trunnions & workpiece fixturing along with a wide range of NIKKEN manufactured rotary work supports and tailstocks to cater for all production expectations.

Computer Numerical Control (CNC) machining is a subtractive manufacturing process that enables manufacturers to accurately and cost-effectively create high-precision parts. CNC machining removes excess raw material from workpieces with cutting tools to create a precise finished product from materials likeplastic, metal, and composites.

These days, product teams have lots of options when it comes to multi-axis machining, from 3-axis to 5-axis to even 9-axis machining. What’s the difference between each type? In this article, we’ll break down the key similarities and differences between two popular types of CNC machining (3-axis vs. 5-axis) — and explain when it might make sense to use one over the other.

After the operator enters milling instructions into a computer, the 3-axis CNC machine will automatically complete the task by using a tool to cut along three axes — X, Y, and Z, or left-to-right, front-to-back, and up-and-down. Both CNC milling and CNC turning fall under the umbrella of 3-axis machining. However, they function slightly differently.

When using a 3-axis CNC milling machine, the material block remains fixed in a vice or on a machine bed. Rotating drills or cutting tools are connected to a spindle and move along the X, Y, and Z axes, removing shavings to accurately form the final component. 3-axis CNC milling machines are excellent for producing most geometries and simple parts.

By contrast, in the CNC turning process, the workpiece is attached to a rotating spindle, and a lathe shapes the component. As the spindle holding the workpiece rotates, a center drill or cutting tool traces the component’s outer and inner perimeters or creates holes along the center axis. Compared to CNC milling machines, CNC lathe turning machines produce parts faster and offer cheaper per-unit costs, which is advantageous for high-volume production runs.

Since a 3-axis CNC machine can only cut along three axes, it may struggle with non-conventional shapes or designs with deep, narrow cavities that are difficult to reach. When processing parts with complex geometries, operators may have to manually reposition the workpiece, which can slow down the processing speed, raise labor and machining expenses, and result in a less-than-perfect finished product.

5-axis machines rely on a tool that moves in five different directions — X, Y, and Z, as well as A and B, around which the tool rotates. Using a 5-axis CNC machine lets operators approach a part from all directions in a single operation, eliminating the need to manually reposition the workpiece between operations. 5-axis CNC machining saves time and is ideal for creating complex and precise parts like those found in the medical, oil and gas, and aerospace industries. There are a few different kinds of 5-axis machines that product teams should be aware of, including indexed 5-axis CNC machines, continuous 5-axis CNC machines, and mill-turning CNC centers.

Like 3-axis CNC milling, the cutting tool only moves along three axes and doesn’t maintain continuous contact with the workpiece in indexed 5-axis CNC machining. However, the machining table and tool head can automatically swivel in two directions between operations. Indexed 5-axis machining is great for manufacturing housings, jigs, and fixtures. It falls somewhere between 3-axis CNC milling and continuous 5-axis CNC machining in terms of speed, precision, and the ability to handle complex geometries.

In continuous 5-axis CNC machining, the cutting tool and the workpiece can rotate and move simultaneously during operation, saving time and allowing operators to manufacture intricate geometries with organic surfaces. Continuous 5-axis CNC machining offers improved surface finish, speed, and dimensional stability, but it has the highest cost-per-part.

Turning mill CNC centers are practically identical to CNC turning machines, with one exception — they’re equipped with CNC milling equipment. The workpiece is attached to a spindle that can either rotate or remain stationary while cutting tools remove material from it. By combining the elements of CNC lathe machines with milling tools, mill-turning CNC centers offer high levels of accuracy and geometric versatility, making them great for creating parts with loose rotational symmetries, such as camshafts or centrifugal compressors.

Not only do these types of 5-axis CNC milling machines offer greater accuracy when machining deeper parts and hardened materials, but they also offer higher yields and faster machining speeds. However, 5-axis machining is more expensive due to the specialized equipment necessary and the need for expert workers.

The main difference between 3-axis and 5-axis milling machines is that the workpiece can be worked on from three axes with the former and five axes with the latter. Both are highly versatile, automated, and replicable production processes that will enable you to quickly and cost-effectively create accurate components. However, you may opt to use one over the other for a variety of reasons.

If you’re on a budget or only need to cut a flat surface, 3-axis machines might be the way to go. In addition to being more affordable than those with five axes, 3-axis machines are simpler to program, so you won’t have to incur the cost of working with expensive expert programmers and operators. Plus, prep time is shorter with 3-axis machining.

If you need to produce a deeper part or one with complex geometry, you’ll probably want to use 5-axis machining. Using 5-axis machines lets you machine the workpiece from all sides — no manual rotation required. With 5-axis machining, you’ll have higher yields, greater accuracy, and increased freedom of movement, as well as the ability to manufacture larger parts faster.

Still on the fence about using a 5-axis CNC machine vs. a 3-axis machine? Fast Radius can help. Our team of experts can talk you through your CNC machining options and help you choose the process that’s best for your project. As a trustedCNC machining partner, Fast Radius also offers high-quality CNC machining capabilities with router-, lathe-, drill-, and mill-based CNC machining equipment. Contact us today to get started.

ATS Systems is a national leading machine tool accessories and automation supplier delivering reliable solutions with unwavering support that increases manufacturing productivity and throughput leading to profitable results for its customers. For over 20 years, ATS has installed over 135K machine tool accessories and automation systems allowing customers to achieve productivity gains of over 50% and increasing profitability.

A 5th axis rotary table is a precision positioning device that is widely utilized in the 3-axis vertical machining center, which turns the original machine tool to a 5-axis CNC machine. The simple installation and seamless interface make the 5th axis rotary table fit numerous 4-axis and 5-axis applications.

A 5th axis rotary table is a precision positioning device that is widely utilized in the 3-axis vertical machining center, which turns the original machine tool to a 5-axis CNC machine. With the rigid cast frame and the ideal torque capacity, the small accessory is flexible in use and supports the various machining operations of the vertical machining center effectively. The simple installation and seamless interface make the 5th axis rotary table fit numerous 4-axis and 5-axis applications.

5th axis rotary table, like the basic level of the rotary table, is designed for accurately locating the work pieces in metal machining operations under rapid and high performance rotation. All kinds of rotary tables are popular to be employed in various metalworking equipment, larger tables and machines in order to perform accurate drilling, milling, boring, or adding other unique features on the metal parts at extremely precise intervals. The tooling operations are smoothly performed around the vertical or horizontal axes. To provide more flexible options of use and also even more precise positioning for machining, there are additional plates like index plates or dividing plates can be mounted on for more applications.

With the rise of modern CNC machines and 5-axis machining productions, there are more and more tailed 5th axis rotary tables or tilt tables manufactured to act as the additional axes, assisting the various cutting tools to remove the materials from the surface of work pieces, especially the place that is hard for the tools to reach. In a 3-axis machine, there are only X, Y and Z axes, which are the linear axes to perform the precision machining. The A, B, C axis in 4-axis or 5-axis machining centers are the additional, rotational working axis which are 180° work around the X, Y, Z axis correspondingly. By employing a 5th axis rotary table, the CNC machining center can add 2 rotational directions to not only increase the versatility of the machines but ensure more ideal accuracy in multiple face cutting.

As mentioned, many shops achieve 5-axis CNC machining by mounting the 5th axis rotary table, which is much more cost-efficient than purchasing a new machine. The easy plug-and-play rotary table is easy to set up as the 4th or 5th axis, permitting a wide variety of complex, high performance machining. The great rigidity of the rotary table permits heavy load. However, the 5th axis rotary table takes considerable space of the 3-axis vertical machining center at the same time. As a result, the work surface is, in the arrangement, more suitable for relatively small parts, which refer to pieces that are smaller than 30 cm or less. On top of that, the operator needs to make sure the control system of the machining center is available for 5-axis operations.

Upgrading the machining center by installing the 5th axis table eliminates the extra finishing jobs performed in other machines or manual adjustments. This is especially beneficial for large volume production. The 5th axis rotary table allows the vertical machining center to create sophisticated and complex contours and add multiple features at desired angles. The arrangement of adding this rotary table to upgrade the machining center is suitable for blade, helical grooves machining and other applications required to create complex features or require critical inspection, like the productions of aerospace, automotive parts and scientific equipment.

The 5th axis rotary table mounted on the vertical machining center provides great rigidity to ensure stable operations. With simple set up, the rotary table can save the cycle time and remove the need of secondary operations. The basic structure of a 5th axis rotary table consists of the disc table where the work pieces are firmly hold and secured, the rigid bearing which can support the forces and loads during the operations, the solid base or bed used for attaching the 5th axis rotary table to the 3-axis machining center or other component, and last but not least, the motor and the

The core of the 5th axis rotary table is the worm gearing meshing with the steel worm that is submerged in the lubricants. The bearings and the worm gears which typically have large diameters have ideal concentricity to ensure the smoothness, durability as well as utmost accuracy. The high performance tooling is performed on the surface provided by the table disc, where the work pieces are stably clamped. Under the guide of the CNC power system and the electric motor, the table disc can position the metal parts at exact intervals. The clamping element, which is the chuck with inner or outer jaws, grips the work pieces firmly to eliminate any movement that will affect the machining. When the work pieces are relatively wider, longer, the operator can choose a chuck with outer jaws to hold them. For more flexible or critical applications, the operator can add dividing plates which can be installed on this table disc.

The worm gear and high precise rotation is driven by the programmed signals from the computer numerical control system. CNC power system ensures the simultaneous 4-axis or 5-axis motion, and the servo control is simple to fully set up. With the software and sequential instructions sent by the CNC system, the machining operations are more reliable and efficient, removing the need and cost of human supervision. The dimension as well as the type of electric motors can determine the actual router accuracy and also the efficiency of the 5th axis table.

CNC rotary tables are a cost-effective alternative for the shops that cannot afford those high-end multi-axis machining centers. Though less versatile and efficient than a CNC machining center, a typical milling machine that incorporates a rotary table is able to carry out many more intricate tasks. In this article, we will walk you through the basic knowledge of the 4th and 5th axis CNC rotary tables, including how they work and what they can do for the shops.

In essence, it is a mechanical device that offers an additional rotational axis to a machine tool. It is typically designed to work with a milling machine so that the machine has the ability to carry out more complex cuts. Provided with a rotational axis, in a sense it combines a milling machine with a lathe. Besides giving an extra axis, rotary tables are also used for indexing and positioning tasks.

Rotary tables were invented in the early 20th century. The construction has not changed much since the invention except the way they are driven. At first, chains were used. But from 1918 on the shaft-driven mechanisms replaced them. As the technology of powered machines and computer control advanced, NC and CNC models hit the market in the late 20th century. CNC controls facilitated precision positioning and indexing.

The primary benefit is the indexing accuracy. In the past, millimeter-scale accuracy was enough for general-purpose machining applications since the part tolerance requirements were not high. Today, medical equipment, military, and automotive components require higher precision. That is why CNC tables with micrometer precision prevail across industries.

The standard CNC rotary tables are also called the 4th axis or 4-axis rotary tables. The 4th axis refers to the rotational axis, their most important feature. It upgrades an existing machine tool with x, y, z dimensions by adding an additional axis.

As mentioned earlier, the working principle of a 4th axis CNC rotary table is similar to the headstock of a lathe. They are both electrically powered to clamp a workpiece and make turns. The CNC system enables precision positioning so that the milling machine can make cuts on the desired surfaces of a workpiece.

An additional fourth axis is beneficial because it can be adjusted for particular amounts of rotary motion. The degrees the table rotates are pre-programmed and accurately controlled by the computer. The other benefit is that it allows the milling machine to work on cylindrical parts. The milling machine can cut grooves, slots, and planes on the outer diameter of a bar.

The precision indexing ability of the rotary table enables the machine tool to cut equidistant holes in a workpiece around 360 degrees across its surface. Repositioning of the workpiece is not required during such an operation. Similar operations such as arc cuts and curved contours can be performed in a run as well.

A 5th axis CNC rotary table provides two additional machining axes to a machine tool. Besides the rotational axis, the 5-axis rotaries have another swinging axis. In other words, the table not only turns but also tips. With two more axes, the machine tool is able to perform multi-plane machining.

The working mechanism of a 5-axis CNC rotary table is simple. As you can see in the image above, the rotary is mounted onto a swivel base. In addition to the swivel, other designs such as a swing bed are also available to provide a tilting axis to the table. Here is a video showcasing the moving axes.

A 5th axis CNC rotary table not only features precision positioning but also eliminates multiple setups that are required for complex machining applications. Compared to the standard CNC rotaries, the 5-axis table covers more surfaces on the workpiece. The milling machine can machine a workpiece on any four of the five axes at the same time, which reduces the production lead time significantly.

One of the key applications of 5-axis machining is mold-making. The ability to achieve intricate surface designs on the workpiece allows for the machine to manufacture molds used in industries including aviation/aerospace, automotive, military/defense, and medical.

The 4th and 5th axis CNC rotary tables have their own pros and cons and are suitable for particular applications. The 4th axis rotaries are apt at precision indexing for simpler designs whereas the 5th axis tables excel at complex designs but the rigidity is compromised and chatter or deflection may take place accordingly. The shops should choose a model that meets their actual requirements.