How much do you know about misconceptions and concepts about high-speed milling?
In the manufacturing industry, there are many misconceptions about high-speed milling, such as the following:
High-speed milling is just a milling machine equipped with a high-speed spindle
The higher the spindle speed, the faster the processing speed
High-speed milling machine is a new technology, just to replace the general traditional milling machine
A 20,000-rpm spindle is sufficient for mold production needs.
High-speed milling is only accelerated by increasing the axial server
High-speed milling can only process electrodes
………
In fact, high-speed milling is a new technology and application philosophy:
If you want to bring out the effectiveness of high-speed cutting, you must work closely with each link. If one of the links is not well matched, you will not be able to bring out the effectiveness of high-speed cutting.
High-speed tool holders and cutters
high speed spindle
Highly powered X, Y, Z axes
High-speed CNC controller
high-speed programming strategy
The situation during high-speed cutting
As the rotational speed increases to a certain level, the temperature and cutting force of the tool will gradually decrease. This phenomenon is used in high-speed milling technology.
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Conventional milling
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High speed milling
Conventional milling
High speed milling
Material removal area is large but slow
Material removal is small but fast
high temperature
generate low temperature
The precision of finished products is low and the tool wears out quickly.
High precision of finished products and slow tool wear
Poor appearance
Good surface
Dispersion ratio of high-speed cutting heat source
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High-speed milling (HSM) and high-performance milling (HPM) machining concepts
Example: Rough machining of hardened steel, material hardness >55HRC
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Application range of high speed milling
1) In order to match the spindle specifications and ensure the stability and safety of processing, the tool diameter does not exceed 16mm (HSK-E40).
2) Compared with traditional milling, the cutting removal rate of high-speed milling is relatively small, which is very suitable for small parts and mold processing applications.
3) It can be used in new processing applications such as thin sheet processing and micro processing.
4) It is a new concept processing method for soft materials or super-hard materials.
Example: An aluminum part with a wall thickness of 0.5mm may not be produced without high-speed milling technology.
1. High-speed matching tool holder and tool
In fact, it's not the machine that's doing the cutting, but the tool! Tools are like car tires, the only parts of the car that touch the ground. Good and suitable tires are the key to success in racing. The selection of cutting tools and processing conditions can be based on the information provided by the cutting tool manufacturer, but the user still needs to make adjustments based on the actual processing conditions.
Criteria for selecting tools:
Diameter (according to workpiece geometric dimensions and accuracy)
Type (roughing, finishing, grooving, 3D contouring, edge machining...)
Shape (ball cutter, round nose cutter, multi-edge milling cutter...)
Materials (high speed steel, cemented carbide, cermet, diamond, cubic boron nitride CBN)
Tool coating (TiN, TiCN, TiAlN...)
Quality (radial runout, shape accuracy, dynamic balance, rigidity)
2. High-speed spindle
In fact, the high-speed spindle is like the high speed and power of the engine in an F1 racing car.
Spindles can be roughly divided into two specifications:
1) With bearings ≥ high torque, the current maximum speed can reach 54,000 rpm.
2) Bearingless (gas driven) ≥ low torque, but very fast speed (>100krpm).
High torque allows the cutting of larger materials, using larger tools and harder materials. High rotational speed allows faster cutting rates and achieves HSM effects.
3. High dynamic performance of each axis
In fact, the bed structure of the machine itself is like the chassis of a car, strong and safe to absorb shock and vibration.
Traditional hard rails can achieve better accuracy through adjustments on the machine table, but they cannot achieve the high-speed processing that linear slide rails can achieve. With high-speed axes and a solid bed structure, acceleration is the key factor. High-acceleration axes reduce time waste, provide better cutting surfaces, and reduce tool wear.
4. High-speed milling controller CNC
In fact, the controller is like a driver, and its operating skills determine the outcome of the car. It requires foresight, sensitivity and quick response capabilities.
5. CAM processing strategy for high-speed milling
In fact, there are many ways to get from one point to the next, but all paths will have different effects on speed, surface, etc.
