Zone: High Speed Machining

High Speed Machining ... Without The Speed

Axial chip thinning is often associated with high speed machining, but this shop uses the same effect to increase metal removal rate with a standard-size end mill run on a moderate-speed machine.

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MFG.com: Marketplace For Manufacturing

(Sponsored content) An MMS InMotion presentation along with a collection of user profiles all describe how machine shops are winning new business using this online resource.

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Most Recent Content in this Zone:

Maximizing Power for High Speed Hog-outs
3/14/2011 Modern Machine Shop: A reader asks a question related to the rated power of a machine tool spindle.
Improving Surface Finish During High Speed Machining
3/14/2011 Modern Machine Shop: Many factors can affect surface finish. This answer to a reader’s question focuses on imbalance and frequency sensitivity.
The Online Optimizer
12/15/2010 Modern Machine Shop: Coming soon: The Machine Tool Genome Project promises to let almost any machine shop use its machining centers more productively. Shops will benefit from tap-test findings without personally tapping any of their own machines or tools.
Software/Tooling Partnership Promises Easier HSM
8/12/2010 Modern Machine Shop: High-efficiency parameters are calculated automatically—partly using a slider that lets the programmer set the level of aggressiveness.
Milling with Air
6/1/2010 Modern Machine Shop: ... not to mention grinding with air. Thanks to high speed spindles powered by shop air, this job shop expands the work its VMCs can do.

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Overview Of:
High Speed Machining

High Speed Machining is, in a way, misnamed. The disciplines involved in high speed machining apply even to low speeds. High speed machining actually has to do with bringing more productivity to the machining process by making it more stable. Because the instability that threatens productivity is often more pronounced at higher speeds, many shops first come to high speed machining because of the challenges of using higher-rpm machining centers. High speed machining has to do with milling. It has two different definitions applying to two different machining challenges: milling complex 3D forms, particularly for dies and molds, and milling large amounts of a metal such as aluminum, particularly to produce aircraft structural parts. In the context of machining complex 3D forms, high speed machining involves taking milling passes with smaller-diameter end mills at very light depths of cuts, but taking these passes at high feed rates. The end mill is often a ballnose tool. The small diameter and very light depths of cuts allow the tool to machine complex features and surfaces precisely, and also to machine hard steels without excessive tool wear. Meanwhile, the high feed rates overcome any loss in productivity resulting from the light depths of cut. The overall metal removal rate in high speed machining is typically the same or better than the metal removal rate that could be achieved through a more typical process involving a larger tool taking heavier depths at a slower feed. In the context of milling away large volumes of aluminum, high speed machining focuses on chatter. Every machining system chatters—that is, every machining system has some specific set of frequencies at which it inherently wants to vibrate. By identifying these frequencies and machining at precise spindle speeds that respect these frequencies, the machining process becomes inherently more stable, allowing the tool to take a heavier depth of cut than it could at other speeds. High speed machining in this context therefore does not mean machining at a higher speed, but instead means machining at a higher metal removal rate by machining at just the right speed.