High Speed Machining

HIGH SPEED
MACHINING
BY
RAVIVARMAN R
I-YEAR M.Tech PDM
DEPARTMENT OF MECHANICAL ENGINEERING
Content
 Introduction
 Definition
 HSM
 Advantages
 Disadvantages
 Applications
 Case Study
 Conclusion
 References
Introduction
 Machining with high speeds (HSM) is one of
the modern technologies, which in
comparison with conventional cutting
enables to increase efficiency, accuracy and
quality of work pieces and at the same time
to decrease costs and machining time.
 Even though High Speed Machining is
known for a long time (first tries were made
in early twenties of the past century) there
are still a lot of questions and less or more
complicated definitions of HSM.
Definition
The first definition of HSM was proposed by

Carl Salomon in 1931. He has assumed that at a
certain cutting speed which is 5 –10 times higher
then in conventional machining.
Definition
 High cutting speed machining
 High rotational speed machining
 High feed machining
 High speed and feed machining
 High productive machining
Finally,
“HSM is a powerful machining method that
combines high feed rates with high spindle
speeds, specific tools and specific tool motion.”
6
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”)
 Value
 Maximizes overall productivity – fewer
process steps, faster machining
 Machining Mold and Dies made of very
hard materials , deep cavities and fine
details typically require time consuming
EDM processes.
 HSM produces high quality finish on milling
machine – reduces need for EDM
electrodes and hand finishing
 Challenges
 How to drive HSM machines to capacity
without breaking tools
 Tool makers cutting data ranges are highly
optimistic
HSM - Truth and Myths
“ The controller runs better with

“You do not need NURBS
more data.”
anymore.”
“ When the machine

chokes and jerks, reduce The tool path must be
“
the number of points by Increase the
“ tangential everywhere.”
lowering the tolerance” amount of stock
being cut if the
finish is dull”
“ Tool must be constantly “ Always use ball end mill.”

engaged with blank”
“ Never cut with the bottom of

the ball end mill”
Demands On The Machine
 Spindle speed range <=40000 rpm

 Spindle power >22 KW
 Programmable feed rate 40-60 m/min
 Rapid travels <90 m/min
 High thermal stability and rigidity in spindle
 Coolant through spindle
 Advanced look ahead function in the CNC
Conventional HSM
The contact time between Contact time is short

tool and work is large
Less accurate work piece More accurate work piece
Cutting force is large Cutting force is low
Low surface finish High surface finish
Material removal rate is low Material removal rate is
high
Cutting fluid is required Cutting fluid is not required
HSM EDM
Material removal rate high Material removal rate is

low
Dimensional tolerance Dim tolerance
0.02 mm 0.1- 0.2 mm
There is no need of Cutting tool has to be
making cutting tool made according to the
according to the contour to contour to be machined
be machined
Advantages
 High material removal rate
 High surface finish
 Increased productivity
 Possibility of machining of very thin walls
 Reduction in lead times
 Low cutting force
 Cutting tool and work piece temperature are kept low
 Connection time between the cutting edge and work
piece is short
 It eliminates the need of coolant
 Reduction of production process
Disadvantages
 High speed machines are more expensive as than

manually operated machines.
 Tools used for high speed machines are quite costly.
 A part of machine which includes machine and
tooling are expensive and requires extensive
justifications.
 Repairing is expensive too.
 High speed machines do not eliminate all the error.
 Internal shapes cannot be machined in High speed
machining.
 Size limitations depend on the size of machine.
Applications
 Industry which deals with the machining of Al to

produce automotive components, small computer
parts or medical devices
 Used to machine such parts as die casting dies,

forging dies, injection moulds and blow moulds,
milling of electrodes in graphite and copper,
modeling and prototyping of dies and moulds.
 Die mould industry which requires dealing with

finishing of hard materials.
Case Study-HSM on Connecting
Rod Die
Measurement NX2 NX3
Operations required 11 7
Rest mill path 4:30 1:30
generation time
Overall Programming 6 hr 2 hr
Time
 Improved In-process work-piece performance

 Automatic cut levels in cavity milling
How did we
 New Z-level Plus path to contour floors while
do it? roughing
 Trochoidal cutting to avoid over-embedding tool
 Holder checking for multiple tools
Conclusion
 HSM is not simply high cutting speed .It should

be regarded as a process where the operations
are performed with very specific methods and
precision equipment
 HSM is performed in finishing in hardened steel
with high speeds and high feeds often with 4-6
times conventional cutting speeds
 HSM is high productive machining in small sized
components in roughing to finishing and in
finishing to super finishing in components of all
sizes.
 Improvement of quality and optimization of cost.
HSM Video
WEBSITE REFERENCE
• UGS PLM Software

http://www.plm.automation.siemens.com
• Vibrafree.com
http://www.vibrafree.com/UHSHM/UHSHM.htm
For more case studies please visit Vibrafree.com. There

a lot of case studies about HSM in pdf format.
Thank you

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HIGH SPEED

The first definition of HSM was proposed by

“ The controller runs better with

“ When the machine

“ Tool must be constantly “ Always use ball end mill.”

“ Never cut with the bottom of

 Spindle speed range <=40000 rpm

The contact time between Contact time is short

Material removal rate high Material removal rate is

 High speed machines are more expensive as than

 Industry which deals with the machining of Al to

 Used to machine such parts as die casting dies,

 Die mould industry which requires dealing with

 Improved In-process work-piece performance

 HSM is not simply high cutting speed .It should

• UGS PLM Software

For more case studies please visit Vibrafree.com. There

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