Determining How Faster Machining Means More Business for You

What is High-Speed Machining?

High-speed machining is much more than just a faster spindle. It is a process that combines high spindle speeds and high feed rates to achieve a very high metal removal rate with lighter passes. It may seem counter-intuitive to remove less material, but great savings in cycle time, tool retention, and energy costs are all resulting benefits. In general, faster machining means more business, but it is important to gauge all the contributing factors in choosing to move into HSM for your operation.

The material being milled, the tool and spindle, and the whole machine must be equipped to tolerate high-speed production, as well as the software to run it. Some minor changes on existing equipment can improve production efficiency, but understanding all the parameters for your operation can make the investment in the right equipment increase efficiencies by over double, and expand your capacity for new contracts.

The Growth of High-Speed Machining
The idea of high-speed manufacturing was developed in the early 1900s when it was discovered that, for a specific workpiece metal, the heat generated peaked at a certain critical spindle speed. The higher speed/lower removal rate was originally used to make molds that had intricate core and cavity geometries.

New CAD/CAM software design technology and multi-axis machining have gradually changed the approach to machining from removing large chunks of material in a set straight path to multi-directional movements that remove small bits of material in rapid, successive runs. Programming, CNC machines, and tools are all challenging one another as they develop faster and faster speeds.
Finish machining no longer needs the added step of EDM (Electrical Discharge Machine) to remove finite material pieces on hardened materials. Although effective, this process added another process and ran at slower speeds for accuracy. Always seeking more efficiencies, manufacturers are embracing this new approach and driving the evolution of HSM with their feedback. This quick review of all the components involved will help make the right choice for your operation.

The Path is as Important as the Speed

One of the typical limitations in machining is approaching corners where stress on the cutting tool and varied amounts of chip removal result in heat and friction. The rpm speed, feed rate, and depth of cut have to be reduced. New high-speed cutting offers a consistent tool engagement and chip load by offering new pathways. Even small diameter tooling can be pushed far beyond traditional limits. Software capacity to run these non-linear cutting paths is imperative to high-speed operations.

Materials
The right tool and the right speed are always based on the material. Not all materials are well suited for the high-speed machining process. Each material has its defined high speed, and each must be programmed to run at different cutting speeds for rough and finish work. The best HSM materials include hardened steels, stainless steel, tool steel, aluminum, and titanium.

Tool Design and Life
One of the biggest benefits of high-speed machining is extended tool life. With less heat and friction, the wear on cutting tools is greatly diminished. However, the high speed requires a focus on balancing and holding. Tool balance should be checked regularly, as a difference of just .01mm can decrease tool life by 50%. Quality of finished will also be affected. Investment in the right holding pieces is as important as the tools themselves.

CNC Machines
Not all CNC machines are suitable for varied materials and speeds. An assessment of the machine tool’s power/torque graph is necessary to determine a machine’s capabilities, especially over time. Older machines will also only have the ability to run at a maximum rpm capacity. The addition of an auxiliary spindle, a flute, or faster software may provide a gradual change to high-speed manufacturing in your existing machine shop. Investing in new machines can be daunting, but assessing your specific needs and utilizing all the tools available to you, it will pay off quickly.

Making the Investment Work
Once you decide to move into high-speed operations, take advantage of all the training available to your employees from the supplier. Visit the machine production facility, or send staff to the software developer for training. Knowing the best use of your new tools will affect your efficiencies the most.
Invite your clients for a tour of your facility. When they see the new capabilities you have this may spark ideas for new projects or designs they never thought possible. Your attention will also yield results from customer referrals and loyalty.

Be sure you make the right choice for your operation to leverage technology and high-speed processes to manage your work with less labour and higher machine efficiency. Consider all the challenges including operator training, parts complexity, material selection, and even available shop floor space to decide just how faster machining means more business for you.

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