RongNa has more than 10 years experience manufacturing custom machining and precision parts for diverse regional and national partners. Our working team uses the latest in CNC machining machine
How Does 5-axis CNC MILLING WORK?
Cnc Machining,Custom Cnc Machining,Cnc Machining Service,Cnc Metal Machining Ningbo Rongna Technology Co.,Ltd , https://www.prototyping-machining.com
We offer advanced 5-axis and 3-axis machining services that significantly increase the range of possibilities for working with complex surfaces and creating parts in numerous shapes and sizes. We provide custom Cnc Milling service and 3-axis, 5-axis CNC milling parts
Milling is the process of cutting and drilling material using a rotating cylindrical tool. This tool is held in a spindle and comes in a variety of sizes and forms. With 5-axis machining, there have two extra rotary axes defined by A, which rotates around the X axis, B, which rotates around the Y axis, and C, which rotates around the Z axis. The combination of additional axes depends on the machine and comes in variations, including AB, AC, or BC.
With 5-axis machining, the table or cutting tool can be tilted, creating the ability to avoid collision with the tool holder and allowing for better access to part geometry. This also ensures improved tool life and cycle time as it helps maintain cutting position and constant chip load. This type of machining offers a push toward single-setup machining, creating shorter lead times and increasing efficiency.
CNC milling is complex machining technique which utilizes several types of pre-programmed CAM and CNC controls to build customized components or parts. We are professional custom CNC milling company and 5 Axis CNC Milling Service provider in China, we offer the manufacturing of precision machined parts and solutions at affordable rates to meet the growing demands of the clients across the world.
We have several machining centers for creating complicated shapes or parts for your products. Contact for more.
In the early 1970s, M. Flemigs and D. Spencer from the Massachusetts Institute of Technology (MIT) discovered that alloys in the solid-liquid phase exhibit low apparent viscosity after continuous stirring, resulting in granular dendrites during crystallization instead of traditional needle-like structures. This slurry is highly deformable and can be filled into complex cavities with minimal force, leading to the development of a new metal forming technique known as semi-solid metal forming. This process can be divided into two main types: rheology and thixoforming. Rheology involves applying pressure to a strongly stirred semi-solid slurry, while thixoforming uses the thixotropic properties of metals by heating pre-solidified slurry to a semi-solid state before press-forming it.
Semi-solid metal forming offers several advantages, such as reducing air and shrinkage holes, improving mechanical properties and mold life, decreasing solidification shrinkage, and enhancing dimensional accuracy. The ease of handling and transporting semi-solid metals also supports continuous and efficient automation, making it more energy-efficient and environmentally friendly than traditional casting methods. Countries like the United States, Western Europe, and Japan have actively adopted this technology. For example, the U.S. military has included rheocasting in its five-year process development plan, while Japan established a research institute between 1988 and 1994 to study semi-solid metal properties and manufacturing techniques, eventually moving towards industrial production. In China, however, the research remains largely at the laboratory stage, with a gap before full-scale industrial application.
The rheological behavior of semi-solid metals is crucial for their preparation and forming. When the solid fraction exceeds 0.05–0.1, the material exhibits non-Newtonian flow. At higher solid fractions (0.5–0.6), the slurry shows non-linear viscoplastic behavior with Bingham flow characteristics. Factors like alloy composition, processing conditions, and solid particle size affect the rheological properties, but the solid fraction has the most significant impact. Apparent viscosity is commonly used to measure these properties. Through shear deformation tests under specific cooling conditions, the relationship between solid fraction and apparent viscosity was analyzed, leading to an empirical formula. This relationship helps optimize the semi-solid metal forming process.
The temperature of the semi-solid metal significantly influences the solid fraction, making precise temperature control essential in practical applications. Additionally, the shear rate during deformation affects the apparent viscosity. Studies on A356 aluminum alloy revealed that the steady-state viscosity follows a power-law model, where the apparent viscosity decreases with increasing shear rate. However, in real-world scenarios, where the filling time is only a few seconds, the dynamic changes in solid particles make the situation more complex. Thixotropy, or the property of becoming less viscous under shear stress, plays a key role in semi-solid metal behavior. This allows the material to behave like a fluid when subjected to high shear stress, making it easier to form.
Various methods are used to prepare semi-solid metals, including mechanical and electromagnetic stirring. These techniques produce solid particles in the range of 50–100 μm. Mechanical agitation is widely used for continuous production, while electromagnetic stirring reduces contamination. Despite its benefits, electromagnetic stirring faces challenges at high solid fractions due to increased viscosity. Japan has developed advanced methods, such as adding small amounts of boron and titanium to aluminum alloys to achieve fine equiaxed crystals. Strain-induced melt activation is another approach used to prepare semi-solid metal raw materials.
Semi-solid metal forming is applicable to a wide range of alloys, including aluminum, magnesium, zinc, copper, steels, cast irons, and composites. It is particularly popular in the automotive industry for producing lightweight and durable components. Companies like Alusisse, Stampal, and Pechiney in Europe, and Koji Co., Ltd. in Japan, have successfully implemented semi-solid die-casting. This method not only improves mechanical properties but also reduces defects and costs. For instance, semi-solid die-cast parts like master brake cylinders and steering housings show superior strength and precision compared to traditional castings.
Forging semi-solid metals is another application, allowing for the production of complex shapes at lower pressures. Alumax Engineered Metal Processes (AEMP) is a leader in this field, producing high-quality automotive parts using semi-solid forging. The process involves cooling the alloy to a semi-solid state, stirring it, and then forging it under controlled conditions. This method reduces machining needs and lowers costs, making it more economical than conventional forging.
Injection Molding with semi-solid metals has also gained traction, especially for magnesium alloys. DOW Chemical introduced a one-step process combining die casting and injection molding, eliminating the need for melting equipment. Thixomat Inc. commercialized this technology, and companies like HPM developed specialized equipment for semi-solid injection. This method produces precise parts with improved performance, making it ideal for automotive and electronic applications.
Overall, semi-solid metal forming continues to evolve, offering sustainable and efficient solutions for modern manufacturing. Its potential for innovation and cost reduction makes it a promising technology for the future.