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2
High Speed Machining
What is it?
Very high tool rpm, small
depths of cut and high feed
rates
Mostly used in milling hard
mold and die steels (hence
term hard milling)
Also appears in airframe
work for different reasons
Different materials
(aluminum)
Used to reduce heat and
material stress during
machining
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High Speed Machining
Value
Maximizes overall productivity fewer
process steps, faster machining
Machining Mold and Dies made of very
hard materials (P20, H13, D2, etc.), deep
cavities and fine details typically require
time consuming EDM processes.
HSM produces high quality finish on
milling machine reduces need for EDM
electrodes, burning and hand finishing
Challenges
How to drive HSM machines to capacity
without breaking tools
Tool makers cutting data ranges from very
safe to highly optimistic - what data do we
use and why doesnt this data always work
for me?
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Hard Milling
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Hard Milling
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Hard Milling - Machine
HSM Capable
Machine Tool
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Hard Milling Cutting Tools
Cutting Tool
Gold coating
TiN High surface hardness
Lubricity
Blue-gray coating
TiCN
Moderate temperatures
High Temperature applications
TiAlN Forms Al Oxide coating -low thermal conductivity
Longer tool life
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Hard Milling Cutting Tools
Ball End Mills rough closer to the part than End Mills
with small corner radius.
Original Part and 30mm End Mill with 30mm Ball End Mill
Blank 1mm Corner Radius
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Hard Milling Cutting Tools
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Hard Milling - Tool Holder
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Hard Milling - Machine Controller
Controller
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Hard Milling Machine Controller NURBS
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Hard Milling - Machine Controller
Smooth Interpolation
Exact positioning
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Hard Milling - Machine Controller
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Hard Milling - Chatter
Chatter Zone
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Proven Integrated Machining Data
Integrated, customizable
machining database enables
storing, retrieving and
associatively using the data in tool
path operations.
NX-CAM for example includes
proven machining data for
commonly used raw materials.
P20 in NX3
More materials coming up in NX4.
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NX Milling what can you do?
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Trochoidal Toolpath
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Material Removal Rate - Roughing
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Metal Removal Rate - Roughing
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MRR & Vertical Engagement Angle
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MRR & Vertical Engagement Angle
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Metal Removal Rate
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Metal Removal Rate - Uniform Blank
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MRR & Z Level Operations
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Constant Surface Speed ??
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Tool Length
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Divide and Conquer
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Case Study - HSM on Connecting Rod Die
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Website reference