5-axis machining of copper is used for complex waveguide cavities, RF components, and electrode manufacturing where the compound geometries cannot be achieved with 3-axis work.
| Parameter | Value |
|---|---|
| Achievable Tolerances | ±0.01 mm |
| Surface Finish | Ra 0.4-1.6 μm |
| Cutting Speed | 100-300 m/min |
| Feed Rate | 0.05-0.15 mm/tooth |
| Tooling Recommendations | PCD ball nose end mills. Sharp uncoated carbide. Polished flute tools to reduce adhesion. |
Manage long chips carefully with through-spindle air
Program consistent engagement to avoid chip nesting
PCD tooling for best surface quality
Consider EDM for very complex cavity shapes
Waveguide cavities
RF resonators
Complex electrode shapes
Particle accelerator components
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