In the manufacturing industry, there are many common misconceptions about high-speed milling:
High-speed milling is just a milling machine 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
20,000 rpm spindle is sufficient for mold production
High-speed milling just accelerates 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 play a high-speed cutting performance, you must closely cooperate with each other. If there is a poor link between them, you will not be able to perform high-speed cutting.
High-speed toolholders and tools
High-speed spindle
Highly powered XYZ axis
High speed CNC controller
High-speed program strategy
High-speed cutting
As the rotation speed increases to a certain degree, the tool temperature and cutting force will gradually decrease. This phenomenon is used in high-speed milling technology.
Traditional milling
Dispersion ratio of high-speed cutting heat source
High-speed milling (HSM) and high-performance milling (HPM) machining concepts
Example: rough machining of hardened steel, material hardness >55HRC
High-speed milling applications
1) The diameter of the tool does not exceed 16mm (HSK-E40) in order to match the spindle specifications and ensure the stability and safety of the machining.
2) Compared to conventional milling, high-speed milling has a relatively low removal rate and is ideal for small parts and tooling applications.
3) It can be applied to new processing applications such as sheet processing and micro-machining.
4) It is a new concept processing method for soft materials or superhard materials.
Example: Aluminum parts with a wall thickness of 0.5mm may not be produced without high-speed milling technology.
1. High-speed tool and tool
In fact, it is not the machine that is cutting but the tool! The knives are like automobile tires and are the only parts of the car that touch the ground. Good and suitable tyres in the race car are the key to success. The tool selection and processing conditions can be based on the information provided by the tool manufacturer. However, the user still needs to adjust the actual processing conditions.
Select the tool's standard:
Diameter (according to workpiece geometry, accuracy)
Type (roughing, finishing, slotting, 3D contouring, edge machining...)
Shape (ball knives, round nose knives, multi-edged cutters..)
Materials (high speed steel, carbide, cermet, diamond, cubic boron nitride CBN)
Tool coating (TiN, TiCN, TiAlN ...)
Quality (Radial Runout, Shape Accuracy, Balance, Rigidity)
2. High speed spindle
In fact, high-speed spindles are like high-speed engines and high-power engines in F1 cars.
The spindle can be roughly divided into two types:
1) With bearing => high torque, the current maximum speed can reach 54,000 rpm.
2) Bearingless (gas driven) => low torque, but very fast (>100krpm).
High torque allows cutting of larger materials, using larger tools and harder materials. High speeds allow faster cutting rates and achieve HSM results.
3. High dynamic performance of each axis
In fact, the bed structure of the machine itself is like the chassis of the car, and it is strong and safe to absorb shock and vibration.
Traditional hard rails can achieve better accuracy through adjustments on the machine table, but it cannot achieve the high-speed processing that linear slides can achieve. High-speed axes and solid bed structure, acceleration is the key factor, high acceleration of the axis to reduce the time waste, better cutting surface, low tool wear.
4. High-speed milling controller CNC
In fact, the controller is like a driver. Its operational skills determine the outcome of the car. It requires forward-looking, sensitive and quick response.
5. High-speed milling CAM machining strategy
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.
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