High-speed machining uses high feed rates and spindle speeds to remove material without compromising part quality and accuracy. The main advantage of HSM is fast cycle time and better tool life.
The main functions of the HSM are as follows:
High metal removal rate (MRR) and minimization of machining time
What is high speed machining (HSM)?
High speed machining is a process where we can achieve high metal removal rates (MRR), light and fast cuts with high feed rates and spindle speeds.
It is a combination of fast movements and well-planned applications to obtain precise parts and better results.
Some key factors you need to consider when it comes to high-speed machining and CNC services are:
- Tool selection and balance
- chip grinding
- Machine Requirements
- Part and tool stiffness
- Material and processing strategy
- CAM Programming
- Cutter selection
Techniques for high-speed machining
High-speed machining is a complicated part manufacturing process and you need to know how to do HSM. If an inexperienced person carries out the process with the right tool, they will not be successful.
HSM is a mixture of techniques used for various applications. These collections of techniques are easy to use and very useful to perform any operation.
Some of the best high-speed machining techniques include:
1: Plunge grinding
It is a type of CAM toolpath and is programmed manually. You could call it a secret weapon to save your skin. The two main properties of plunge grinding are:
- You can achieve a stiffer cut by converting XY plane forces into up and down Z axial forces.
- Twist drills allow you to remove more material than an end mill.
Roughing or plunge milling is best for deep pockets when side pockets cause greater tool deflection. Plunge milling allows you to carry out roughing work on old machines in the workshop. Some disadvantages of plunge grinding are:
- Center cut and conventional twist drill
- 2D Plunge Roughing vs. 3D
- Wavy edges
2: Trochoidal machining/milling
This CNC milling process can be used to mill deep pockets, narrow cavities, and grooves. Trochoidal machining is an excellent solution for machining grooves in hard, exotic materials such as titanium and Inconel.
The main advantages of trochoidal machining are:
3: Side steps
These are connections that can be effective for transitioning between adjacent toolpaths at high feed rates. They tend to produce a sharp crossing movement at the end of the pass. Simple circular motions can be sharper at high feed rates. In the last decade, parallel scanline surfacing has been used to finalize models with multiple surfaces.
A suitable solution at moderate feed rates is to use a simple loop path as alternate sharp turns between scan passes.
High speed machining machines
Before starting an HSM process, it is important to inspect a machine, torque table or power tool. The machine must be able to meet all requirements. A high speed machine suitable for 300-M may not be suitable for other material such as titanium. Therefore, an appropriate strategy must be adopted for HSM operation to obtain accurate and high-quality parts.
Many machines are suitable for high-speed machining. It can be a 5-axis milling machine or a 3-axis milling machine. Some machines that can be used for high speed machining are as follows:
1: Micron Mill-S-400-U
Mikron Mill-S-400-U was specially designed for high-speed machining and allows for high-quality surface finishes and high precision of parts. The unique intelligent temperature management system ensures the machine operates accurately during run time and at high milling speeds.
Micron high-speed milling centers are 10 times faster than traditional machines. The compact design provides exceptional accessibility to all areas of the machine for maintenance work.
The power components of the HSM and the machine base are optimally cooled, which improves thermal stability in the production environment.
2:Matsuura LX-160
It is a high quality linear machine with a short cycle time. The optimized rigidity of the LX-160 ensures a high level of precision and a stable machining platform. The LX-160 reduces cycle time and all axles of the Matsuura LX-160 are driven by one motor. This allows you to achieve rapid acceleration and high speed.
The rare features and intelligent protection system make the LX-160 easy to use and enable optimal implementation of HSM operations and power techniques.
High-speed machining tools
HSM requires advanced editing tools. There are different types of high speed machining tools for different applications. Requirements are different in each industry, for example in the automotive industry; Horizontal machining tools are used for high volume production.
On the other hand, in the mold and injection molding industry, the surface quality, accuracy and precision of parts are of great importance and require a different set of high-speed tools.
The choice of tool depends on many things. This depends on
These factors determine the best tool for high-speed aluminum machining. The most important thing is stability and well-balanced tools. Otherwise, vibration may occur and tool life may be reduced.
HSM tool selection begins and ends with a workpiece. Tool balance is very important and indirectly affects tool and spindle life. Some steps for balancing the tool are
It is necessary to select the right tool with tight tolerances and speed. The success of HSM operation depends on many factors, such as:
HSM tools must be designed for high speeds and some high speed rules of thumb may apply. A small percentage change in tool diameter would be effective in chip grinding. This also allows for higher speeds.
Material for high speed CNC machining
Many industries use HSM, such as aerospace, medicine and aviation. HSM has a wide range of materials to meet the needs of each application. Some common material types are:
1: Aluminum oxide
It is one of the basic cutting tool materials for high-speed aluminum machining. It is used due to its chemical stability at high temperatures and superior hardness. It has low breaking strength.
2: Ceramic cutting tool
Ceramic is extremely resistant to abrasion and high temperatures. These are non-metallic materials that are available in two classes:
3: Diamond
It has high hardness, excellent chemical stability and thermal conductivity. The most expensive tool material is natural diamond because it has sharp blades. Natural diamonds are mainly used in:
There are four types of diamond that we can use in high speed CNC machining and high speed aluminum machining.
High speed machining applications
High-speed machining can be used to directly produce prototypes, low-volume components, and cutting tools for engine parts production. The main objective of HSM is to reduce production costs by increasing productivity.
The other objective of HSM is to increase global competitiveness through short lead times and lead times.
1: Aviation industry
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The requirements of the aviation industry are high durability and reliability, and the aircraft manufacturing and design process has many limitations. Aviation is one of the most complicated and complex technologies, and HSM techniques are mainly used in the aviation industry. The use of high-strength aluminum alloys is also increasing to implement the latest processes and techniques. The main reason to choose HSM in aviation and aircraft manufacturing is:
These factors make HSM a better choice for the aerospace industry than other milling techniques and methods.
2: Medical industry
Medical instruments, tools and parts require greater precision and accuracy, and you can achieve this high level of precision with high-speed CNC machining. It can be used for orthopedic implants, joint implants, molds or surgical instruments. Material requirements may vary depending on high quality standards.
Many CNC service providers serve the medical industry and have extensive knowledge in high-speed CNC machining and high-speed machining advancements.
Medical parts manufacturers are becoming more efficient without compromising quality.
3: High-speed machining for the automotive industry
High-speed machining offers a wide range of products and uses for diverse applications. In recent years, high-speed aluminum machining has been increased to reduce weight and cost in the automotive industry.
It is mainly used for small batch production, complex parts and mold making. The automotive industry demands high-speed milling and high-volume part production, and HSM is a good choice to meet these requirements.
The focus of the automotive industry is on producing fast and cheap vehicles. High investments require the implementation of different methods.
Auto parts are manufactured using high-speed machining and many companies that offer CNC services can be a good option for manufacturing your auto parts.
Get high-speed editing with Wayken
HSM is an emerging machining process and technological solution for mass production of parts. WayKen offers products in large quantities without compromising quality, and we know how to provide manufacturing solutions to our customers. Wayken is your best choice for building a progressive, profitable business. You get better parts with superior surface finish, longer tool life and faster material removal.
Contact us for more information. WayKen helps you boost your business.
