The 5-axis CNC machine geometry milling technology enhances rotation and milling in all its axis to provide intricate shapes. However, milling these complex parts requires a small cutting tool to remove unwanted feed parts. This cutting tool requires high revolutions per minute (RPM) to achieve efficient feed removal. Unfortunately, the CNC 5-axis technology is not equipped with such machining speed, hence a limitation.
However, this limitation can be apprehended with high-speed air spindle integration with the CNC five-axis technology. Modifying a 5-axis CNC machine with a high-speed air spindle provides sufficient power for milling, cutting, and maintaining the tool path, even in tight angles and hard materials. Such a powerful integration duo improves the RPM of the CNC machine with high productivity and efficiency by harnessing their capabilities to machining intricate parts.
Faster Material Removal Rate
As previously said, the 5-axis CNC machine technology is slow, restraining its ability to milling and cut intricate shapes and hard material. Hence, high-speed air spindle modification is essential to upgrade this feature and improve efficiency.
Technically, the machine’s performance is measured by the material removal rate, which is the volume of the material/feed it can remove per minute. This rate is determined by the width of cut, depth of cut, and feed rate; all of these determine the volume of the material which will be removed per minute.
Generally, it was thought that increasing any of these parameters would improve the speed and efficiency of the CNC machine axis. The problem here is that increasing any of these parameters beyond optimal level will cause one or more of the machine axis to become stiff, and the machine begins to struggle with cutting and milling.
Also, you shouldn’t think of the CNC machine axis as a golden status of destruction that can mill and cut feed material at any angle and rate. It consists of spinning blades that repeatedly hit the material, generating a force that builds up between the machine and the workpiece.
This force may cause the working axis to begin to bend, and when they come across a larger chunk that requires a more significant force, positive feedback occurs, which will cause greater damage to the axis and the machine in general.
Therefore, integrating a high-speed air spindle into the CNC 5-axis machine is essential to prevent this damage and achieve a more incredible speed and power of machining. With the optimal level of axis machine parameters and the natural speed boost of the air spindle, the machine can mill intricate parts and shapes without any fear of damage to the spindle or any other part of the five-axis technology.
Milling of Complicated Geometries with Complex Angles
The combination of the highly-efficient speed booster ability of the air spindle and the five-axis machining process of the CNC machine has proven to increase the speed of rotation and field of view of the machine.
The increased rotation and field of view of the 5-axis machine enhance the machining of complex and sophisticated geometries because of its milling speed and access to deep holes.
With the spindle speed booster, you can mill at speeds between 25,000 and 90,000 RPM. This reduces the cycle time by 6-10 times compared to the traditional spindle in the CNC 5-axis machine.
This reduced cycle times accelerate the production rate, increase production yield, and increase business profits. All of these are expected because the high-speed air spindle increases the axis’s rotation speed.
In addition, numerous air spindles are slim enough and have long bodies to reach deep holes and approach difficult-to-reach geometric parts without losing rigidity. This enhances the ability of the combination to produce complicated geometries with complex angles.
Combining the speed and ability to reach complicated parts is vital to manufacturing industries that produce parts used in electrical works and aerospace engineering.
Optimal CNC Power Spindle Potential
Manufacturers have tried common spindle speeders, coolant spindles, and electrical spindles to improve the CNC machine axis RPM. And every time, they fail in the process due to increased friction and thermal build-up.
The nominal high speed of these spindles cannot maintain the high RPM for a relatively long period. The friction and thermal build-up effect lead to a limited duty cycle, burnout, and adverse thermal effects.
The significant difference between this spindle-speed booster and the high-speed air spindle is in their structure. The air spindle technology contains two moving parts: the air-cooled grease-packed ceramic bearings and the proprietary spindle, while the speeders contain gears with high-frequency vanes. These components of the speeders experience high friction corresponding to thermal build-up; the parts expand thermally or may burn out.
The air spindle succeeds in this aspect; its direct drive eliminates heat and duty cycle, hence increasing durability. Therefore, if combined with the 5-axis CNC machine, it will maintain optimal CNC power spindle potential, and efficiency will not drop drastically.
Combining the 5-axis CNC machine technology and high-speed air spindle is a hallmark of evolution in the machining industry. This technology offers enhanced production of intricate geometries with unparalleled precision and accuracy, tool durability, and unlocking the next level of excellence in production.