Taking CNC Machining to the Next Level

Modern CNC machining (computer numerical control) is a subtractive manufacturing process – material is precisely removed from a workpiece to create parts. In the past decade, the spotlight often shifted to 3D printing (additive manufacturing), but CNC technology has quietly undergone its own high-tech renaissance. Today’s CNC systems are smarter and more capable than ever, evolving through multi-axis designs and intelligent integrations that push precision and productivity to new heights. This article explores how advanced 5-axis and 6-axis CNC machines, paired with innovative solutions like programmable coolant nozzles, are taking machining to the next level in speed, complexity, and efficiency. We’ll discuss the benefits of multi-axis systems, the challenges of high-speed machining, and a breakthrough solution for chip removal – culminating in how these advancements, supported by NMB/PIB’s precision components and partnerships, empower smarter manufacturing.

Multi-Axis Evolution: 5-Axis and 6-Axis Advantages

CNC machining has traditionally meant 3-axis mills or lathes, but adding axes has dramatically expanded what one machine can do. More axes = more flexibility: a single modern CNC can maneuver a tool or part around multiple orientations, enabling fabrication of complex geometries in one setup. In recent years, 5-axis and even 6-axis CNC machining centers have become far more accessible, no longer prohibitively expensive, and they deliver higher efficiency than classical 3-axis machines. By rotating around additional planes (beyond X, Y, and Z), these systems can approach the workpiece from virtually any angle. This means features that once required multiple machine setups or fixtures can now be completed in one continuous operation. Fewer setups not only shorten cycle times, but also maintain accuracy – the part doesn’t need to be repeatedly re-indicated, so tolerances stay tight and surfaces come out smoother.

Higher yields and efficiency: Multi-axis CNCs also boost throughput. With optimized tool paths and tangential cutting angles, 5-axis machines remove more material per pass, improving material removal rates. Cycle times drop, and each machine yields more finished parts per tool load. In fact, industry adoption of 5-axis technology has been growing steadily (about 6% CAGR from 2021–2025) as manufacturers seek greater precision and automation. The ability to produce intricate components without manual reorientation gives shops a competitive edge – complex aerospace brackets, medical implants, or automotive prototypes that once seemed impractical can now be milled or turned with relative ease. In short, multi-axis capability translates to higher precision, better surface finishes, and increased production output from the same machine footprint.

Challenges of High-Speed CNC Machining

Pushing CNC machining to go faster and output more isn’t without its difficulties. Higher spindle speeds and feed rates greatly increase productivity, but they also amplify certain manufacturing challenges. Chief among these is the management of metal chips (swarf) generated by the cutting process. Unlike 3D printing, CNC is subtractive – every cut produces metallic debris that must go somewhere. At modest speeds, standard coolant flow and gravity might clear chips adequately. However, in high-speed or continuous machining, chips accumulate much more rapidly and can become a serious problem.

Chip buildup and tool wear: If not removed, swarf can pile up around the cutting zone or cling to the tool and workpiece. These hot, abrasive metal chips can damage cutting edges and scratch part surfaces. Faster cutting multiplies the volume of chips, raising the risk of tools getting re-cutting debris or jamming. The result can be accelerated tool wear, poor surface finishes, or even scrapped parts due to gouges or out-of-tolerance features. For example, a machining operation might start producing rough, inconsistent finishes as chips recirculate in the cutter’s path instead of clearing out. In extreme cases, chips can wedge in machine ways or fixtures, risking unplanned downtime to clear a jam.

Downtime and quality issues: Maintaining part quality at high speeds means dealing with chips efficiently. Operators must periodically pause machining to evacuate accumulated chips (via air blast, manual vacuuming, etc.), which interrupts production. This downtime can partially offset the gains from faster cycle times. Additionally, every pause or manual intervention is an opportunity for error and adds labor overhead. Chip issues can even lead to machine damage if swarf infiltrates moving components or clogs lubrication passages. In high-volume manufacturing, the stakes are especially clear: even a seemingly small defect rate caused by chip interference (say 1%) can translate to enormous scrap counts. For a plant outputting 100 million components per month, a 1% defect rate means a million faulty parts – an extremely costly outcome. Thus, as CNC machines accelerate and automate, swarf management becomes a critical bottleneck to address for sustaining quality and uptime.

Programmable Coolant Solution: The Wavy Nozzle System

To overcome the chip clearance challenge, engineers have turned to smarter coolant delivery. MinebeaMitsumi’s Wavy Nozzle is an innovative programmable coolant nozzle system designed to dramatically improve swarf removal during CNC machining. Unlike a fixed coolant nozzle that sprays in one direction, the Wavy Nozzle can move and aim its coolant jet dynamically under CNC program control. This electromechanical device (powered by a precision stepping motor) oscillates the coolant stream in a sweeping or “waving” motion to flush chips away from the cutting zone. Guiding chips in a deliberate direction, it prevents them from getting re-cut or tangled, in contrast to simply blasting fluid at high pressure and hoping for the best.

Multiple modes for any operation: The Wavy Nozzle features three programmable modes of operation – fixed, sweep, and kick – which can be tailored to each machining step. In fixed mode, it behaves like a standard nozzle, but sweep mode pivots the jet back and forth continuously, and the kick mode adds an oscillation with variable speed. The “kick” mode is unique in that it can accelerate the nozzle momentarily during its stroke, giving a harder impulse to dislodge stubborn chips. These modes can be optimized per tool or cut: for instance, a slow sweeping action might be used during a fine finishing pass to gently carry away small chips, whereas a rapid kick burst could accompany a deep drilling operation to eject long, curled chips. Operators or automated CNC programs can switch modes on the fly, and even teach the nozzle motion specific to a setup (using a handheld controller to record an optimal spray pattern).

Extending tool life and quality: By actively removing debris, the Wavy Nozzle keeps the cutting path clear, which maintains consistent cutting forces and temperature. This leads to more uniform surface finishes and protects the cutting edges from chip-induced wear. With chips evacuated, tools stay sharper longer and are less prone to chipping or breakage, directly prolonging machine tool life. An effectively cleared work area also means the machine can run continuously with minimal intervention. According to MinebeaMitsumi’s internal production data, introducing a moving coolant nozzle had a dramatic impact – defect rates in one high-precision machining line dropped from around 1% to just 0.02% after adopting the Wavy Nozzle solution. This nearly eliminated scrap due to chip-related issues, showcasing how better chip control translates to major quality improvements.

Minimal downtime, easy integration: The Wavy Nozzle system not only improves chip removal, it does so in a way that integrates smoothly with existing equipment. Because it “sweeps” chips out with directed fluid motion, it does not require extremely high-pressure coolant or large external pumps/compressors like some chip-blasting solutions. The unit itself is compact, designed to fit into CNC machine enclosures without major modifications. In fact, its compact and self-contained design allows it to be retrofitted onto many existing CNC lathes and mills or installed on new machines with equal ease. The versatility was a deliberate choice – by keeping the device small and using standard interfaces, MinebeaMitsumi made sure even a small machining center or an older machine can upgrade its coolant nozzle to this intelligent system. This plug-and-play integration means shops can gain the benefits of automated chip management without needing an entirely new machine. MinebeaMitsumi has even collaborated with machine OEMs to embed the Wavy Nozzle into factory offerings; for example, it partnered with FANUC to integrate Wavy Nozzle units into the ROBODRILL vertical machining centers, providing customers a turnkey solution for improved chip control

Originally published at Taking CNC Machining to the Next Level

Ready to take CNC performance to the next level? Our engineering-led sales team will help you specify, source, and integrate the right components quickly and confidently. We partner with your engineers to review your application, recommend chip-control and coolant strategies, and select precision parts—miniature bearings, stepper/BLDC motors, encoders, seals—that hit your targets for tolerance, surface finish, and cycle time. We can also provide cross-references, sample kits, rapid quotations, and supply-chain plans from pilot through volume production.

Contact PIB Sales at [email protected]

FAQ

Q: What are the practical manufacturing benefits of using multi-axis CNC and better chip control?

A:

• Complex parts in one setup: 5-axis/6-axis machines can handle intricate geometries without multiple re-fixturing, reducing setup time and error.
• Higher yield & less scrap: Improved chip removal (e.g. via Wavy Nozzle) prevents surface defects and tool damage, which means more good parts per batch and fewer rejects – in one case scrap rate dropped from ~1% to 0.02% with a dynamic nozzle.
• Longer tool life: Clearing chips reduces cutter wear and heat build-up. Tools stay sharp longer, extending intervals between tool changes and lowering tooling costs.
  

Q: How can advanced coolant systems like the Wavy Nozzle be integrated into existing machine tools?

A:

• Plug-and-play design: The Wavy Nozzle unit is compact and self-contained, allowing it to be added onto most CNC machines without major modifications. It fits into standard coolant plumbing and enclosures.
• Flexible installation: It can be retrofitted to older equipment or specified with new machines. Its control can operate standalone or be linked with the machine’s CNC program via simple I/O signals for mode switching.
• No extra infrastructure: Unlike high-pressure washdown systems, Wavy Nozzle doesn’t require large compressors or pumps – it uses normal coolant pressure, simplifying integration and keeping energy usage low.
  

Q: How does better chip control translate to higher productivity in CNC machining?

A:

• Reduced downtime: Effective swarf removal means CNC machines need far fewer stoppages to clear chips. Operators spend less time pausing production for cleanup, so machine utilization stays high.
• Consistent performance: With chips kept at bay, machining can proceed at optimal speeds without unexpected slowdowns due to clogged tools or alarms. This stability allows manufacturers to fully exploit high feed rates and spindle speeds for maximum throughput.
• Quality and yield gains: Good chip control prevents the cascade of problems (tool wear, heat, poor finish) that lead to rework or scrap. Parts come off the machine right the first time, boosting effective output. In fact, eliminating chip-related defects significantly improves overall production efficiency and output

For more information, contact PIB at www.pibsales.com.