{"id":2527,"date":"2020-06-02T09:00:03","date_gmt":"2020-06-02T13:00:03","guid":{"rendered":"https:\/\/robodk.com\/blog\/?p=2527"},"modified":"2024-11-12T11:51:41","modified_gmt":"2024-11-12T16:51:41","slug":"machining-axes-cuts-production-costs","status":"publish","type":"post","link":"https:\/\/robodk.com\/blog\/machining-axes-cuts-production-costs\/","title":{"rendered":"Why Increasing Machining Axes Cuts Production Costs"},"content":{"rendered":"\n

It’s official! Adding extra axes to your machining process can make it more efficient and reduce costs. Here’s why it works.<\/strong><\/p>\n\n\n\n\n\n\n\n

Things change constantly in the world of manufacturing. New technologies arrive, old technologies improve, and we need to update our processes to keep up.<\/p>\n\n\n\n

One change that has been happening recently is an increase in the number of axes that can be used in CNC machining. According to the current trends<\/a>, the newest technology is allowing multi-axis machining to become even more accessible than it has ever been before.<\/p>\n\n\n\n

But, you might be wondering, are more axes really better?<\/p>\n\n\n\n

Well\u2026 yes.<\/p>\n\n\n\n

Adding extra axes to your machining process can add a whole load of benefits, including improved efficiency and reduced costs.<\/p>\n\n\n\n

You can add extra axes either by investing in a multi-axis CNC machine or with robot machining.<\/p>\n\n\n\n

Which is the better option? To answer that, let’s first look at the problems of traditional machining.<\/p>\n\n\n\n

5 Problems With Traditional 3-Axis CNC<\/h2>\n\n\n\n

Traditionally, CNC machines have 3 programmable axes, often X, Y, and Z. These allow you drill, mill, or otherwise transform your workpiece in 3 dimensions. Some reduced-axis machines (e.g. engraving machines) also come with just 2D or 2.5D capability.<\/p>\n\n\n\n

3D machining is great for many common operations in manufacturing. However, it can also be very restrictive to have only 3 axes.<\/p>\n\n\n\n

Here are 5 problems which arise with traditional CNC machines:<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

1. Requires More Setups<\/h3>\n\n\n\n

Fewer axes mean more setups. Unless your products only require extremely simple machining, it is likely that you need to change the position and\/or orientation of the parts to achieve all of the required cuts.<\/p>\n\n\n\n

Each extra setup directly affects the productivity of the machining cell. This is particularly problematic with low batch sizes (which are becoming more common) where up to 90% of the machining time can be taken up by setups<\/a>.<\/p>\n\n\n\n

2. More Hands-On Time<\/h3>\n\n\n\n

More setups don’t just reduce the productivity of the machine. They also reduce the productivity of workers. Every setup requires a human worker to spend their valuable time on a non-value-added task. They could spend this time more productively elsewhere.<\/p>\n\n\n\n

Streamlining your changeovers<\/a> can help to reduce this time, but it’s far more effective to remove as much hands-on time as possible.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

3. Needs Custom Fixturing<\/h3>\n\n\n\n

3-axis machines are restricted in the orientation at which they can approach the workpiece. If a machining operation requires a slightly offset orientation, this often means that you need to design and fabricate custom fixturing.<\/p>\n\n\n\n

Custom fixtures are fine for very large batch sizes. However, they can add a huge amount of work for every setup. This can significantly increase the time each part takes and the cost.<\/p>\n\n\n\n

4. Increased Steps Per Operation<\/h3>\n\n\n\n

Any manufacturer would agree: the fewer machining steps you have, the better. Many of the principles within the practice of Design for Manufacture<\/a> are devoted to simplifying machining operations and reducing the number of machining steps that are required.<\/p>\n\n\n\n

3-axis machines often unnecessarily increase the number of steps compared to machining technologies which have more Degrees of Freedom.<\/p>\n\n\n\n

5. Increased Lead Time and Product Cost<\/h3>\n\n\n\n

All of the above problems can negatively affect the overall manufacturing process leading to increased lead times and a higher product cost. Every time a technician needs to spend their valuable time with a new setup and every time a custom fixture must be made, it can impact directly on the bottom line.<\/p>\n\n\n\n

Why Extra Axes Reduce Costs<\/h2>\n\n\n\n

The increasingly popular solution to these problems is to add extra axes to your machining operation.<\/p>\n\n\n\n

There are two ways to achieve this, as we’ll outline below, but first let’s look at why more axes can reduce costs.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

The 6 Degrees of Freedom Sweet-Spot<\/h3>\n\n\n\n

We often think of the world as being in 3 dimensions. But, in reality, there are 6 dimensions required for fully flexible machining<\/a>:<\/p>\n\n\n\n