Characteristics of High Speed Machining

High Speed Milling

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Chip Forming

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High Speed Machining

HIGH SPEED MACHINING

CHARACTERIZED BY CUTTING SPEEDS

THAT ARE 5 TO 10 TIMES HIGHER

THAN IN CONVENTIONAL MACHINING

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Cutting Data

Material to be machined

Aluminium

Bronze , brass

Cast iron

Steel

Titanium alloys

Ni alloys

10

30

100

300

1000

3000

10000 m/min

30,000 ft/min

Vc

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Workpiece

Tool

HSM Process

▪ Process conditions at the cutting edge

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Consequences of High Speed Machining

Increase of the Cutting Speed

Increase of the Cutting Zone Temperature

Change of Chip Formation and Chip Removal

Machining

Increase of the metal removal

rate

Reduction of the machining time

Heat dissipation through the

chips

Tool

High thermal load

High wear with

increasing

material strength

Workpiece

Less heating of the workpiece

Higher dimensional accuracy

Improved surface quality

Thin walled workpieces

possible

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Advantages of High Acceleration

high

average feedrate

R

R

va f

2

= acceleration

too

l-life

high

accuracy

low

tool-wear

faster

machining times

improved

qualitylower tool costs

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ap

High Strength Materials – Arc of Contact

Increase of the cutting zone

temperature

High Risk

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High Speed Milling Strategies

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High Strength Materials – Arc of Contact

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Steep Taper versus HSK

▪ Hollow Cup Taper (HSK)

• Excellent static and dynamic

stiffness

• Excellent axial and radial

accuracy

• Excellent suitability for high

speeds (inside clamping)

• Low mass and stroke

▪ Steep Taper (ISO, BT, CAT)

• Relatively poor stiffness

• Poor axial accuracy

• Not suitable for high speeds

(outside clamping)

• Large mass and large stroke

• Widespread

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Tool holders suitable for HSM

▪ Interface between tool holder and

cutting tool using

• Collets

• Hydraulic expansion technology

• Hot air or induction shrinking

technology

• Power shrinking technology

• Threading technology

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Process Chain

▪ Knowledge of HSM

Technology

▪ Powerful CAD/CAM

System

▪ Optimized Milling Strategy– Constant Z-Level Milling

– Constant Load of the

Milling Cutter

– Continuous Tool Action

– No Abrupt Changes of

Direction

– Careful Initial Action

– Contour-Parallel or

Helical Milling

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Advantages of 5x Machining

▪ Ability to machine complex shapes in a single set-up!

▪ Greater machining productivity compared to multiple setup jobs in 3x

▪ Less human error of incorrect alignment and therefore less scrap

parts.

▪ Use of short tools, avoiding of vibration higher quality on surface finish

no therefore no hand finish.

▪ Increasing of tool life and reducing of breakages:save of tooling and

fixture costs.

▪ Huge saving time in the drilling of holes, due to one set-up which

allowing drilling to be completed much more quickly.

▪ Great and new 5-Axis cycle support from all major CAM systems

▪ All in all everything with a much faster lead time.

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5x Simultaneous High SpeedMachining

⚫ Conventional mechanical rotary/tilt axes do not match

feedrates and acceleration of linear axes.

⚫ Fast spindles, fast linear axes but slow rotary axes.

⚫ Conventional rotary axes limit feedrates.

⚫ Benefits of HSM are lost.

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Technical Data of Rotary/Tilt Table

▪ Rotating speed (°/sec ) 1500

900

▪ Rotating speed (min-¹) 250

150

▪ Acceleration (rad/s2) 300

100

▪ Acceleration (°/s2) 17,200 5,700

▪ Max. range (°) nx360

+/- 110

▪ Work torque (Nm) 217

686

▪ Brake torque (Nm) 500

2‘000

▪ Positional accuracy A 8"

12“

▪ Dimension of pallets ITS 148

▪ Max. workpieces weight 25 (kg)

rotating tilting