Understanding 3+2 Machining: A Cost-Effective Alternative to 5-Axis CNC Machining

5-Axis CNC Machining

CNC machining is renowned for precision, speed, and versatility. While 5-axis CNC machining excels in handling complex geometries, 3+2 machining offers a cost-effective alternative for many applications, balancing efficiency and accuracy with reduced expenses.

What is 3+2 Machining?

Traditional CNC mills require re-fixturing parts for multi-surface access, consuming time and increasing error risks. 3+2 machining eliminates this by adding rotational axes (A and C) to the fixed X, Y, and Z axes, allowing better access to cutting surfaces without repositioning parts manually.

Benefits of 3+2 Machining

1. Efficiency

  • Fewer setups lead to faster turnaround times.
  • Shorter and more rigid tooling ensures faster speeds.
  • Improved access to complex geometries reduces machining time.

2. Enhanced Accuracy

  • Minimal re-fixturing allows for tighter tolerances.
  • Reduced human intervention eliminates positioning errors.

3. Cost Savings

  • Reduced machining time lowers overall costs.
  • Accurate cuts minimize material waste and rework.

4. Complexity Handling

  • Improved endmill access enhances precision on intricate designs.
  • Ideal for parts with angled features or complex housings.

Applications for 3+2 Machining

3+2 machining is particularly suited for:

  • Injection molding molds
  • Complex housings
  • Parts with angled or multi-sided features

3+2 Machining vs. 5-Axis CNC Machining

Feature3+2 Machining5-Axis CNC Machining
CostMore affordableHigher due to advanced capabilities
ProgrammingEasier to programMore complex programming requirements
ApplicationsHandles multiple sides but not all sidesHandles extremely complex geometries
Setup RequirementsFewer setups, ideal for most partsContinuous toolpath control for faster results

Design Considerations for 3+2 Machining

For most designs, 3+2 machining offers an excellent balance of cost, speed, and accuracy. However, parts with extreme geometries may require the advanced capabilities of full 5-axis CNC machining.

CNC machining offers precision, speed, and versatility with various materials, including plastics and metals. For more complex parts, advanced milling techniques like 3+2 machining bridge the gap between traditional machining and full 5axis CNC machining, providing a cost-efficient solution.

 

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Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Fatigue Strength (MPa)
Aluminum 6061602.68193117
Aluminum 6063732.721468.9
Aluminum 70501472.83490160
Aluminum 7075(Aerospace Grade)1502.81503159
Aluminum MIC-6652.7105N/A
Aluminum 5052602.68193117
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Fatigue Strength (MPa)
Copper 10165 - 908.89 - 8.9469 - 36576 - 90
Copper C11065 - 908.8969 - 36576 - 90
Copper C17280 - 858.25515 - 585275
Copper C26060 - 828.53103 - 44190
Copper C36063-1308.49124-310138
Brass CZ12190 - 1608.47360 - 500220 - 360
Brass CZ13170 - 1408.5340 - 480200 - 350
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Modulus of Elasticity (GPa)Elongation at Break(%)
Stainless Steel 17-73887.812752046
Stainless Steel 3012178.0320521240
Stainless Steel 3031608.0324020050
Stainless Steel 3161878.0320519340
Stainless Steel 3322008.0329419644
Stainless Steel 4163607.89622009.5
Stainless Steel 4205067.8104020011.5
Stainless Steel 440C495 - 6537.8450 - 1900204 - 2152.0 - 14
Hardness(Shore D)Density (g/cm^3)Modulus of Elasticity (GPa)Tensile Strength(MPa)Elongation at Break(%)
HDPE50 - 760.92 - 0.990.565 - 1.511 - 433 - 80
UHMW-PE54 - 1200.8 - 1.80.3 - 1.111.6 - 403.5 - 800
PVC801.16 - 1.651.82 - 7.033.45 - 73.12 - 330
ABS/Nylon Blend641.04 - 1.210.9 - 5.327 - 1003.1 - 230
Acrylic600.7 - 1.30.95 - 3.7925 - 851 - 85
Nylon 6676 - 881.02 - 2.70.6 - 2510 - 981 - 300
PTFE11 - 700.7 - 3.350.392 - 0.750.86 - 41.470 - 650
PEEK62 - 941.26 - 1.722.14 - 2411 - 1251.7 - 100
POM-H811.423.27530
POM-C791.412.86740
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Modulus of Elasticity (GPa)Elongation at Break(%)
Titanium(Grade 1)1204.5170 - 31010324
Titanium(Grade 2)2004.51276 - 44810320
Titanium(Grade 4)2654.51480 - 65510515
Ti-6Al-4V(Grade 5)3794.43110011410
Bronze11.6 - 4205.6 - 1469 - 80072.4 - 1380 - 70
Zinc Alloy (Zamak 5)916.720870 - 1007
Steel Alloy AISI 43403887.8597220012.1
Nickel Alloy175 - 2408.44414 - 75820716