5 things you need to know about 5-axis machining from DMG MORI

1. 60% fewer setups, 30% shorter cycle times. Versus 3-axis machining, 5-axis machining centers from DMG MORI typically reduce the number of setups required to machine complex parts by 60%. Fewer setups and shorter setup times mean less operator intervention and part handling, facilitating unattended/lights-out machining nights and weekends – a boon when manufacturers struggle to fill skilled-labor positions. By optimizing cutting conditions, up to 30% less time is needed to machine the same part, increasing overall equipment effectiveness (OEE), productivity, and profitability.

Medical devices and implants often feature complex geometries and must be machined to exacting tolerances and finishes, making geometric dimensioning and tolerance (GD&T) control of paramount importance. By reducing part setups, 5-axis machines from DMG MORI also reduce setup errors and, depending on multiple variables, can provide up to 25% higher part accuracy. Fewer setups also make it easier to blend machining (visual steps) on all sides of a block without requiring the operator to manually shift the workpiece. Better finishes mean less secondary finishing (benching) too.

3. 50% fewer specialized tools and lower workholding costs. Since the machining center rotates the workpiece to access multiple axes, fewer specialized tools (e.g., extra-long drills or cutters) are needed to reach otherwise difficult to access areas. By optimizing tool reach and geometries, chatter is reduced, tools run faster and more accurately, fewer setups are needed, and tooling requirements for a given job can be halved.

Also, workholding costs can similarly be reduced when moving from 3- to 5-axis machining.

4. 70% higher productivity with added automation. Additional automation gives 5-axis productivity an even greater boost – up to 70% more parts per shift. DMG MORI’s palletization system simplifies workpiece handling and setup in the machine while ensuring part location accuracy. Add the PH Cell rotary pallet-storage system and up to 40 pallets can be prepped and queued to be machined. All pallet setups and programming occur outside the machine envelope, greatly reducing downtime between workpiece changeovers. Pallet loading/unloading is done from the side, leaving front door and top of machine access to load extra-large workpieces or should the robot need service. Additional tools like the CELOS paperless workflow/job-management system moves programming and verification to the office, while the DMG MORI Messenger remote diagnostics speeds troubleshooting.

5. Save energy, money, the planet. DMG MORI’s own manufacturing operations are carbon-neutral. Its products are designed for high energy efficiency and built using renewable energy so customers’ own operations are greener. One 5-axis CNC center – such as the company’s DMU eVo Linear, NTX 500, and DMP 35 favored for medical machining – can often replace several 3-axis machines, further lowering energy consumption, operating, and service/maintenance costs, and part wear and tear.

There really are compelling reasons to move from 3- to 5-axis machining. Contact us to learn more.

For more information: 
DMG MORI
https://us.dmgmori.com