5-AXIS

BUYER’S GUIDE

A step-by-step guide to simplify the evaluation

of 5-axis technology for your shop floor.
IT’S TIME TO REFLECT ON YOUR JOURNEY AS A MANUFACTURER.
Along that road, you have more than likely found advancements in equipment,
machining tools, and even technologies that have acted as incremental
steppingstones for your next endeavor – and now you are looking to 5-axis
machining to make the next jump.

We understand moving to a 5-axis machine is a large commitment, one that may

come with many questions and even some hesitations. Many shops, however,
view the purchase of a 5-axis machine as a must-have, not a luxury that’s out
of reach. The adoption of this technology gives them a viable means to increase
production, lower part cost, and achieve a higher ROI.

The goal of this 5-Axis Buyer’s Guide is to provide a step-by-step, thought-

provoking evaluation of 5-axis technology. It’s important to take the time to
investigate what questions you need to ask about a prospective 5-axis machine
so that a sound buying decision can be made. So, let’s get started!

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1. THE RIGHT CHOICE: WITH 5-AXIS
MACHINING COMES CONFIDENCE
First, congratulations on your choice to adopt 5-axis machining. It is proven that shops that
capitalize on the abilities of 5-axis machining find a quick elevation of confidence, reputation,
and, most importantly, revenue potential. There are immediate ROI factors that are achieved
with the adoption of a 5-axis machine tool, including:

• Fewer setups: Streamline the machining process to a single setup on a single machine.
This eliminates the need to change tools, adapt programs, or physically move the part –
giving a shop more active cutting time. Reducing the number of setups also removes cost
from the manufacturing process.

• Higher accuracy: 5-axis machining allows for the ability to machine multiple sides of a part
in one workholding to minimize movement between stations and reduce chances for error.

• Reduced footprint: By condensing machining operations into a single machine, the need
for multiple machine tools to produce a single part is greatly reduced – freeing up valuable
shop floor real estate and decreasing maintenance touchpoints.

• Faster throughput: Eliminate tedious setups, movements between machines, and fixture
prepping to create quicker throughput and higher part accuracy.

• Reduced scrap and part rework: By condensing the number of setups within production,
5-axis machines lessen the risk of human and cumulative error and, in turn, reduce
potential downtime.

• Repeat and grow business: Consistently please customers with shorter lead times and
by meeting tight-tolerance specifications. Gain the potential to expand revenue with an
expanded book of business, part quantities, or even manufacturing more lucrative parts for
new industries.

The requirements for part accuracy continue to tighten with continuing technological
developments and heightened expectations within industry segments. Quite simply, machine
shops that cannot produce a consistently accurate part within appropriate lead times risk the
potential of losing business to those that can. This means choosing the correct category of a
machine, such as a 5-axis machine tool, will provide you with the ultimate advantage – keeping
loyal customers returning and new customers coming.

EXPLORE MORE DETAILS AROUND THIS TECHNOLOGY WITH OKUMA’S

5-AXIS GUIDE →

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2. CAN I AFFORD A 5-AXIS MACHINE?
UPFRONT AND TOTAL COST OF OWNERSHIP
It is common practice for shops to make a smaller financial investment by retrofitting a
current 3-axis machine with a rotary table to incorporate 4-axis or even 5-axis capabilities.
Although limiting, once this has proven effective, those shops begin to look for the competitive
advantage a full 5-axis machine tool can provide.

LEARN MORE ABOUT BRIDGING THE GAP TO 5-AXIS MACHINING →

Fortunately, the advancements that have occurred within 5-axis machining over the last
decade have truly made this category of machine tool affordable for all. Within the 5-axis
category, price ranges can be dramatically different depending on the level of sophistication,
features, automation, and the list continues. Many machine tool builders offer entry-level 5-axis
machine tools, yet it is important to conduct a side-by-side comparison to ensure build quality
and performance are not being jeopardized on less expensive 5-axis machine tools.

Although the initial amount of the capital expenditure, or price tag, is an immediate criterion
in the purchase of a 5-axis machine tool, shop management must think about the costs of
sticking with older technology. Owners understand if they do not have 5-axis capabilities within
their machine mix, they simply cannot keep the cost of parts in a competitive range and risk
losing business to those that have 5-axis machines.

Equally, when investing in the right high-quality 5-axis machine tool, the savings realized and
the extra revenue earned by using a 5-axis machine tool will quickly recover the upfront cost of
the machine. Testimonies from shop owners and managers frequently tell of the same success
commonalities around the long-term benefits, including productivity gains, quicker throughput,
savings in tooling costs, and reduction in maintenance expenses.

“Although the initial investment for our Okuma

5-axis machines may have been a little
more, the number of satisfied customers we
continue to have has begun to pay for the
machine exponentially.” – Don Miller, QSM

READ MORE →

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3. WHAT TO LOOK FOR IN THE PHYSICAL
CHARACTERISTICS OF A 5-AXIS MACHINE TOOL
When conducting a comparison of 5-axis machine brands or even models, do not hesitate to ask
your local sales or technical representative for a cutting demo, references, and even to conduct
a time study – they should be happy to help with any of these areas of interest to prove their
product offerings are a correct fit for your application. During your 5-axis machine review, be sure
to compare the following physical details and components:

• Size and space requirements: A 5-axis machine can reduce the need for multiple machine
tools on a shop floor, but it is also important to review aspects such as placement of the tool
changer, door opening, coolant tank, and chip conveyor system to better understand the
space requirements for daily operations and maintenance activities.

• Machine structure and build: Be sure to ask questions about the build type and how it plays
into the structural integrity and longevity of the 5-axis machine tool. Examine the width of the
machine base without the sheet metal enclosure, making sure the casting fully supports the
width of the machine to ensure a sturdy, stable foundation.

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• Machine tool mass: It is proven that a heavier 5-axis machine
will always make a consistently stable cut because there are more
places for the cutting energy to dissipate within the casting –
creating less noise and vibration that extends tool life as well as
results in a higher-quality part.

• Thermal stability: A goal should be to minimize the amount of

heat generated – and deal with the heat that can’t be eliminated
– to maintain quality and reduce scrap, no matter what the
environmental conditions are.

• Construction of the trunnion: A trunnion can be supported

differently between models and manufacturers. While the single
and dual support trunnion styles both offer 5-axis machining
capabilities, dual support offers greater strength and stability
when doing heavy-duty machining. For larger 5-axis machines, it
is important to have the trunnion driven on both sides of the tilt
axis of the trunnion. Be sure to consider the trunnion and rotary’s
drivetrain gear setup as there are several types, including torque
motor, hypoid gear, or cam-roller gear, in addition to the strength
and backlash that each style presents will vary.

• Automation compatibility: Within a shop, the usage and

applications supported by a 5-axis machine tool can shift over
time, and automation may become a viable option for growth
opportunities. With that in mind, during the purchase conversations,
be sure to specify if your 5-axis machine tool should be spec’d to
have (or accept future) automation components such as zero-point
work holding systems, automatic pallet changers, as well as robotic
cells and packages. Also, consider the layout of the table and
trunnion to ensure adequate operator access to the machine and
control and future placement for automation systems.

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4. OPERATOR CONTROLS AND SOFTWARE
AIDS AVAILABLE ON A 5-AXIS MACHINE
When 5-axis was first introduced, the learning curve for machinists was greater than it is today.
Although 5-axis programming is more complicated than programming on a 3-axis machine, an
experienced programmer can easily make the shift to 5-axis with a short training session and
by taking advantage of simplified controls, tool path verification, and virtual simulation systems
such as digital twin software. These software aids speed up the conventional process from part
concept to making chips, greatly improving spindle utilization and uptime.

To aid in flexibility, most 5-axis machines are programmed via CAD/CAM programming and not
necessarily on the CNC control itself. The operator simply executes the program that has been
created and verified by a programmer. Utilizing offline tool-path verification can reduce the skill
set needed and the demands placed on the operator using machine modeling, simulation, and
intelligent technologies that make 5-axis machining much more approachable. Many shops
choose to incorporate software systems into their sophisticated 5-axis machine tools, such as:

• CAD/CAM: Not all CAD/CAM software is designed for higher-end 5-axis machining. Ensure
your CAD/CAM partner and the person that is driving this software internally are properly
aligned with the chosen machine and your shop’s exact applications.

• Tool path verification: This serves as

a visual safeguard by conducting pre-
machining simulations of the CNC
machining process to detect errors,
potential collisions, or areas of inefficiency.
It is important to ensure your selected tool
path verification software correlates and has
quality post for your exact machine tool.

• Collision Avoidance Software: Conducted

in real-time, this software mitigates the risk
of collisions between the tool, workpiece,
and other components operating within the
machine tool as it approaches and moves
away from the part.

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• 5-Axis Auto Tuning: This allows for a better understanding of the machine’s alignments
and pivot points so compensations and adjustments can be made to accurately tune out
any geometrical errors due to thermal growth or environmental distortion.

• Tool Center Point Control (TCPC): This software aid compensates for the differences on
where the part is programmed versus where it is actually physically located. By performing
rotational algebra, it translates the tool-tip path defined in the part program to ensure
cutting angles and offsets remain positioned correctly.

• Tool Posture Control (TPC): During contouring, this software smooths vectors so that the
tool tip is not swinging or repositioning. This smooths out the cutting path to ensure proper
geometry and smoother transitions.

Software integration can help enhance productivity with less machine downtime, setup time,
and trial cutting time.

A final consideration and question to raise

during the purchase decision is the unity of
all controls and software – in other words,
have they been tested, tried, and proven
compatible when all working in unison on
the machine tool?

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5. PROPER GUIDELINES FOR 5-AXIS
MAINTENANCE REQUIREMENTS
If you invest in a 5-axis machine tool, maintaining the machine to the proper specifications
and intervals is critical to the machine’s longevity and integrity. These suggested routines and
timelines are outlined in the machine’s operation and maintenance manual. All 5-axis machine
tool manuals should include safety, best practices, geometry, alignment, measurements, and
periodic testing checks.

Besides familiar maintenance routines such as cleaning and replacing filters, coolant pins,
and O-rings, 5-axis machines will require a few specialized considerations when servicing –
many of those concentrate on the trunnion due to its various axis movement areas. Preventive
maintenance on a 5-axis will include additional lubrication checkpoints, fill points, locations,
and intervals, as well as any potential friction-additives that may be required. If your 5-axis
is running in a 24/7 lights-out production environment, understanding how long the required
preventive maintenance cycle will take your machine offline should also be an investigative
point during the buying decision so that scheduling can be implemented without sacrificing
productivity.

Shops can see savings in overall maintenance cost due to a single 5-axis machine tool
replacing multiple machines within a part’s manufacturing process – all of which once required
their own preventive maintenance and touchpoints if failures occur.

6. EXAMINE THE TRAINING AND AFTER-

SALES SUPPORT PROGRAMS
It’s no secret that embarking on a 5-axis machine will require training from a trusted source
or mentor. With the addition of physical components found within a 5-axis machine (such
as a trunnion) and the supporting software applications for this category of machine tool,
questions will arise regarding how to operate, maintain, and service the 5-axis machine.
To address the differences encountered with a 5-axis machine, a well thought out and
comprehensive training program is vital to a shop’s success. Although each machine will
come with a manual, and there are many viable training courses and videos online, there’s
no substitute for an in-person interaction and coaching session that is available through an
OEM or their regional distribution partners.

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Access to a collaborative environment during all stages, including pre-sales, training, and post-
sales activities, should weigh heavily on the journey to 5-axis machining. Pay close attention to
the level of service that is offered at each of these stages - as the level of support seems to be
a large differentiator within the 5-axis community.

If a problem or issue cannot be solved in the field, a reputable machine tool builder will offer
to ship the defective component (even a trunnion) to their facility for an inspection, repair,
or rebuild – while at the same time shipping a replacement directly to the shop to eliminate
unnecessary downtime. Having an exchange program in place provides confidence and uptime
to those operating a new technology, such as 5-axis machine tools.

7. QUESTION THE WARRANTY FOR THE

5-AXIS MACHINE TOOL
Not all machine tools are created equal, and the warranty provided is a testament to this fact.
Be sure to inquire about the standard warranty on any 5-axis machine and ask for details
around the parts, software, and controls. A manufacturer that is confident in its components,
build structure, and integrated elements will have an unwavering warranty.

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8. TRUST YOUR MACHINE TOOL
MANUFACTURER
When looking to purchase a machine tool, it is important to feel that a long-term, mutually
beneficial relationship is being cultivated. Manufacturers choose to go to market through
varying channels, including direct or through partnership networks. In all cases, time should be
taken by all parties involved to fully understand your shop’s business goals and the resources
required to obtain them. Be comfortable with the attention and answers you are receiving
during your evaluation of 5-axis machining – they should represent what is best for you, your
shop, and your future.

If you have questions that are not addressed in this 5-Axis Buyer’s Guide, we would love to speak
with you! Contact our knowledgeable 5-axis machining experts at your local distributor. →

WHAT MAKES OKUMA

5-AXIS MACHINES A
REAL GAME CHANGER?
As a single-source provider of machine, control,
spindles, drives, and more, Okuma 5-axis
machine tools are technological marvels that
deliver swift and efficient part production for
the tightest tolerances. Here’s how our machine
tools are different:

• Open-Architecture OSP Control

• Thermo-Friendly Concept
AFFORDABLE,
• Greater Machine Mass COMPACT
GENOS
• Intelligent Technologies
M460V-5AX
• Best-in-Industry Warranty Size: 2,160 x 2,810mm
• Automation Integration (85.04 x 110.63in)

© 2022 Okuma America Corporation

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