Principles of Machining Sequence Planning for 5-Axis Machining

Geometric Feature-Based Sequence Optimization

The geometric complexity of 5-axis machining demands a systematic approach to sequence planning. For components with hierarchical features such as aerospace impellers, the machining sequence should follow a “base-to-detail” principle. Initial roughing operations should first address large-volume material removal using high-efficiency strategies like helical milling or layer-by-layer contouring. This establishes a stable foundation for subsequent operations by minimizing deformation risks caused by residual stress.

When processing multi-curvature surfaces like turbine blades, the sequence must consider curvature continuity. A recommended approach involves dividing the surface into zones based on curvature radius. Areas with gentle curvature (radius >50mm) can be machined using larger-diameter tools with higher feed rates, while tight-curvature zones (radius <20mm) require smaller tools with finer stepovers. This zonal processing prevents tool deflection in complex areas from affecting previously machined regions.

For components with undercut features, the sequence should prioritize accessible areas before rotational axis adjustments. In medical implant machining, for example, initial operations use 3+2 positioning to machine primary surfaces with standard tools. Only after these areas are completed does the sequence transition to full 5-axis simultaneous motion for undercut finishing, minimizing tool changes and setup times.

Process-Stage-Driven Sequence Strategy

The “rough-semi-finish-finish” multi-stage approach remains fundamental in 5-axis machining. During roughing, material removal rates should maximize efficiency while maintaining process stability. For titanium alloy components, this typically involves high-speed milling with ceramic end mills at axial depths of cut (DOC) reaching 80% of tool diameter and feed rates exceeding 1,500mm/min. The key is balancing aggression with thermal management through controlled coolant application.

Semi-finishing operations require transitioning to tools with smaller diameters and finer geometries. A common strategy employs ball-nose end mills with diameters between 6-12mm, operating at reduced DOC (0.5-2mm) and stepovers of 10-30% tool diameter. This stage focuses on establishing uniform stock allowances for finishing, typically leaving 0.05-0.2mm depending on material hardness and surface finish requirements.

Finishing demands precise control over tool orientation and cutting parameters. For optical mold components requiring surface roughness below Ra 0.1μm, the sequence incorporates constant scallop height algorithms that dynamically adjust stepovers based on local curvature. Tool axis vectors must maintain optimal engagement angles (typically 10-15° front tilt and 5-10° side tilt) to prevent rubbing and ensure consistent cutting conditions across the entire surface.

Material-Specific Sequence Adaptation

Different materials require tailored sequence strategies to optimize tool life and surface integrity. When machining aluminum alloys, the sequence can leverage high-speed machining (HSM) principles with spindle speeds exceeding 18,000rpm and feed rates up to 4,000mm/min. The aggressive cutting parameters are counterbalanced by using tools with polished flutes and sharp cutting edges to minimize built-up edge formation.

For nickel-based superalloys used in aerospace components, the sequence must prioritize thermal management. Initial roughing employs trochoidal milling patterns with 30-50% radial engagement to distribute cutting forces evenly. The sequence incorporates frequent tool retraction cycles to facilitate chip evacuation and coolant penetration in deep cavities. Finishing operations use coated carbide tools with specialized geometries to withstand the high cutting temperatures while maintaining dimensional accuracy.

Composite materials like carbon fiber reinforced polymers (CFRP) demand a fundamentally different sequence approach. The sequence should begin with roughing using diamond-coated tools to prevent delamination, followed by semi-finishing with compression routers that apply downward force to stabilize the material. Finishing employs specialized end mills with up-cut geometries to produce clean edges without fiber pullout, with the sequence carefully controlling feed rates to prevent thermal degradation of the resin matrix.

Established in 2018, Super-Ingenuity Ltd. is located at No. 1, Chuangye Road, Shangsha, Chang’an Town, Dongguan City, Guangdong Province — a hub of China’s manufacturing excellence.

With a registered capital of RMB 10 million and a factory area of over 10,000 m2, the company employs more than 100 staff, of which 40% are engineers and technical personnel.

Led by General Manager Ray Tao (陶磊 ), the company adheres to the core values of “Innovation-Driven, Quality First, Customer-Centric” to deliver end-to-end precision manufacturing services — from product design and process verification to mass production.

Advanced Digital & Smart Manufacturing Platform

Online Instant Quoting: In-house developed AI + rule engine generates DFM analysis, cost breakdown, and process suggestions within 3 minutes. Supports English / Chinese / Japanese.

MES Production Execution: Real-time monitoring of workshop capacity and quality. Automated SPC reporting with CPK ≥1.67.

IoT & Predictive Maintenance: Key machines connected to OPC UA platform for remote diagnostics, predictive upkeep, and intelligent scheduling.

Fast Turnaround & Global Shipping Support

| Production Cycle | Metal parts: 1–3 days; Plastic parts: 5–7 days; Small batch: 5–10 days; Urgent: 24 hours | | Logistics Partners | UPS, FedEx, DHL, SF Express — 2-day delivery to major Western markets |

Sustainability & Corporate Responsibility

Energy Optimization: Smart lighting and HVAC systems

Material Recycling: 100% of aluminum and plastic waste reused

Carbon Neutrality: Full emissions audit by 2025; carbon-neutral production by 2030

Community Engagement: Regular training and environmental initiatives

Official website address：https://super-ingenuity.cn/