Limitations of machining hard materials

on conventional milling machines

• The structural strength of the machine is not enough to sustain the force that are produced during the machining
of hard materials.
• The tool material required for machining hard materials are very expensive and are not easily available
• For materials like cubic boron nitride, boron carbon nitride and other super-hard materials cannot be machined
on the conventional machine tools as no other tool material can be made to machine these materials other then
diamonds, carbide and ceramic inserts(expensive alternative).
• Even if hard materials are machined on conventional milling machines the dimensional accuracy can’t be
achieved.
• The process then would be carried out at very high temperatures which would affect the metallurgical properties
of the machine tool components
• The time required for machining hard materials will be very high and hence would affect the rate of production.
• The tool life of the tool used in machining hard materials would be drastically reduced as the tool would be getting
worn out more rapidly.
• Special cutting tools with modified tool geometry are need with coating of alloying element for increasing the tool
strength
Solutions for machining hard
materials on milling machines
Some modifications to the conventional milling machines can be done to accommodate
the machining of hard materials:
• Machine tool:
• The base construction and the individual components of the machine, such as the drive
train, spindle, and CNC system, must be able to handle high cutting forces with a rigid
base with good vibration damping characteristics.
• Tool-holders:
• hard milling requires a large range of speeds. Collet chucks in addition to offering
maximum flexibility, are easy to handle, provide excellent shock absorbing
characteristics and offer an excellent range of clamping diameters.
• These are suitable for aggressive roughing and semifinishing of hardened materials.
Continued
• Cutting tools:
• For roughing hardened materials, four-flute end mills or higher are recommended.
• The selection of cutting tools should be short with short flute lengths along with a helix
angle of approximately thirty degrees which has proven to be optimal for chip flow and
dispersal of heat.
• Hard milling creates a great amount of stress on the tool from high heat and abrasive
wear.
• To help overcome these stresses, coatings of a protective layer on the tool, substantially
increasing its life.
• The most common coatings are titanium nitride (TiN), titanium carbon nitride (TiCN),
titanium aluminum nitride (TiAlN) and titanium aluminum carbon nitride (TiAlCN)
Alternatives to conventional milling
machining for hard materials
• Metal laser melting: The innovative process has a number of clear benefits, ranging
from the ability to manufacture complex geometries and manipulate materials that
are difficult to machine, to the creation of components without the use of tools in
very short periods of time and with extremely minimal waste of material.
• Electron-beam machining: is a process where high-velocity electrons concentrated
into a narrow beam are directed toward the work piece, creating heat and
vaporizing the material. EBM can be used for very accurate cutting or boring of a
wide variety of hard materials.
• Electrical discharge machining: Material is removed from the workpiece by a series
of rapidly recurring current discharges between two electrodes, separated by
a dielectric liquid and subject to an electric voltage.
Refrences date: 25/04/2017
• http://www.mmsonline.com/articles/the-hard-milling-imperative
• http://www.moldmakingtechnology.com/articles/the-secrets-to-hard-milling-success
• https://archive.org/stream/J._Paulo_Davim_Machining_of_Hard_Materials/J._
Paulo_Davim_Machining_of_Hard_Materials_djvu.txt
• http://www.metalworkingworldmagazine.com/metal-laser-melting-by-toolcraf/
• http://www.mmsonline.com/articles/edm-vs-milling-in-diemold-machining
• http://www.thomasnet.com
/articles/custom-manufacturing-fabricating/mechanical-vs-laser-cutting
• https://me-mechanicalengineering.com/electron-beam-machining-ebm/
• http://mechanicalbuzz.com
/laser-beam-machining-process-applications-advantages-disadvantages-1000.html
• http://www.min.uc.edu/ucman/research/electrical-discharge-machining/