High Speed Machining

By

CMTI

.
 HIGH SPEED MACHINING
 High spindle speed
 High feed rate
 High ATC speed
 High table index speed
 High pallet change speed

 Low depth of cut

 Economical & Technical
factors for development of
HSM
 Materials

 Quality
 Processes
 Design & Development
 Complex Products
 Production Equipments
 HIGH SPEED MACHINING vs.
CONVENTIONAL MACHINING

 Dynamic Performance- 2 to 3 times greater.

 Cutting Speed- 25 times greater than HSS.
 Spindle Speed- 6 times greater.
 Feeds- 6 times greater.
 Productivity- 200% - 300% greater.
 HIGH SPEED MACHINING-
CHARACTERISTICS

 HIGH SPINDLE SPEEDS-10,000 TO 60,000

RPM

 HIGH CUTTING SPEEDS –300m/min to

1000m/min.

 FEED RATES > 40 - 60m/min.

 LESSER DEPTH OF CUT

 HIGH SPEED MACHINING-
CHARACTERISTICS

 LOWER CUTTING FORCES.

 HEAT DISSIPITATION THROUGH CHIPS.

 HIGH SPEED CONTROL WITH HIGH SPEED

DATA AND LOOK FORWARD CAPABILITY TO
AVOID DATA STARVATION.

 HIGH ACCELERATION AND DECELERATION –

0.8 TO 1.2 M/SEC2.
High speed machining
Influencing parameters
HSM is also very often used in
direct production of

 Small batch Production

 Prototypes and Pre – series in Al, Ti, Cu for the
Aerospace industry, Electric/Electronic
industry, Medical Industry, Defense Industry
 Aircraft Components
 Automotive Components, GCI and Al
 Cutting and Holding tools
One of the function of HSM is to
eliminate jerk (left) and provide
smooth acceleration & decelerations
(right)
5 – Axis Breton Machine
 High speed machining–typical
parameters
Spindle speed feed rates - 10,000 to 40,000 rpm
Rapid - 60 m/min
Contouring - 40 m/min
Pallet change time - 6.3 sec.
Pallet index time - 2.5 sec.
Spindle speed acceleration /
deceleration - 1.3 sec.
Tool change time - 0.45 sec.
Cutting speeds - 3,000 m/min
W.P hardness - Upto 60 HRc
Cutting tool material - CBN
 MACHINE TOOL REQUIREMENT

– HIGH STRUCTURAL RIGIDITY WITH HIGH DAMPING

– RELATIVELY LIGHT TO MOVE FAST.
– ALL AXES MOVEMENTS IN TOOL. JOB IS
STATIONERY.
– THERMO SYMMETRICAL VERTICAL SLIDE WITH
AUTOMATIC TEMPERATURE COMPENSATION
– CERAMIC ANGULAR CONTACT BALL BEARINGS FOR
SPINDLES.
– SPINDLES ARE COOLED AND DYNAMICALLY
BALANCED ALONG WITH TOOL.
– HSK HOLLOW SHANK TAPERS WITH INTEGRAL
MOTOR SPINDLE
Requirement of a High speed
spindle system
Spindle
 CONTROL SYSTEM

* NEAR ZERO FOLLOWING ERROR FOR

SHARP CORNERS

* FAST RESPONSE 32-BIT PROCESSOR.

* DIGITAL SERVO DRIVES.

* MAX. POSITION FEED BACK PULSE

RATE (UPTO 40 MILLION).
Linear Motors
– COIL ASSEMBLY WITH A
FLAT ARMATURE FITTED
ON TO AXES SLIDES.

– LINEAR MOTORS
ELIMINATE BALL LEAD
SCREWS/BEARINGS ETC.

– CAPABLE OF VERY HIGH

TRAVERSE RATES 120
m/min.
Brushless Linear Motor
 Linear Motor benefits
 Non – Contact. Force is generated
through an air gap
 Simplicity. Only one moving part, no
mechanical linkages
 High velocity and acceleration
 Smoothness
 Accuracy and repeatability
 Maintenance
TOOLING FOR HSM
HSK basic Nomenclature
 HSM for various tool materials and
tool diameters
Tool diameter Tool material
(mm) Carbide Cermet CBN
Cutting speed Vc (m/min)
300 600 1000
Spindle speed (r/min)
6 16000 32000 53000
10 10000 20000 32000
16 6000 12000 2000
Feed rate (mm/min), (0.1-2mm/ tooth)
6 4000 8000 13250
10 2500 4750 8000
16 1500 3000 5000
 High speed machining
(cutting speed Vs work piece
material)
 HIGH SPEED MACHINING - CUTTING
TOOLS

 SOLIDCARBIDE END MILLS WITH

COATING.
 CERAMICS.
 PCBN-POLY CRYSTALINE CUBIC
BORON NITRIDE.
 HIGH SPEED MACHINING - TOOL
COATING

 TIN-TITANIUM NITRIDE COATING

(2000Hv).
 TiCN-TITANIUM CARBONITRIDE
COATING(2700Hv)
 TiAIN- TITANIUM ALUMINIUM NITRIDE
COATING (3200 Hv)
 High speed machining
- Applications
 Mold and die machining
 Micro machining
 Precision industries
 Fabrication of aluminum and non- ferrous components
 Large volume production
 Automobile industries
 Large volume metal removal
 Aircraft industries for machining or thin wall
construction of Al & Mg alloys
 Machining of carbon fiber filled plastic components
 High speed machining – products
 Complete machining of hardened steel dies up to 60hrc
 Forging dies : crankshaft, camshaft, links, connecting rods
 machining of steel and aluminum alloys :
 Plastic injection : instruments, door & roof panel, bumpers &
accessories for car industry, household appliances.
 Machining of copper and graphite electrodes
 Die cast tooling : cylinder head, carters, engine blocks, rims
 Machining of steel and cast iron
 Metal sheet dies : car body industry
 Milling, digitizing and measuring of models
 Styling applications : car, motorcycles, etc..
 Tire moulds : sidewall engraving, tread machining.
High Speed Machining Centre
Filter Head
Filter Head
HIGH SPEED MACHINING-APPLICATIONS

DIES & MOULDS

Forging Dies
Diecasting Dies
Milling of Electrodes in Graphite and Copper
Injection Moulds and Blow Moulds
 HIGH SPEED MACHINING - ADVANTAGES

 MACHINING OF HARDENED STEEL (UPTO 60HRC)

 GOOD SURFACE FINISH-NEEDS NO POLISHING-
SAVES 35% OF CYCLE TIME.
 LOW THERMAL INFLUENCE ON TOOL & WORK
PIECE.
 HIGHER DIMENSIONAL ACCURACY.
 LOWER CUTTING FORCES.
 LONGER TOOL LIFE.
 ELIMINATES EDM AND GRINDING OPERATIONS.
 SHORTER MACHINING TIMES.
 In Conclusion……

 Higher speeds, feeds and lesser depth of cut.

 Spindle speeds from 10,000 to 60,000 rpm
 Ideal for die & mould industry to machine directly on 60
Hrc Steel material
 Suitable for machining thin sectioned parts as most of
the heat is dissipated through chips, leaving no
distortions on the work piece
 No manual polishing required after machining
Question & Answer
Thank You.