5/8/2018 Six Points You Must Know about High-Feed Milling : MoldMaking Technology

Six Points You Must Know about High-

Feed Milling
A look at why the benefits of high-feed milling can significantly outweigh the potential
challenges.

Article Post: 4/1/2012

TODD MILLER

High-feed milling focuses on removing as much material as

possible in the shortest amount of time. It’s a process that’s
Related been around for a while and can open doors to more lucrative
Suppliers business opportunities. Unfortunately, some manufacturers
have moved away from the process due to what they consider
Seco Tools, LLC reliability concerns. And it’s true, if not applied properly, high-
feed milling can create some unfavorable results.
For those willing to take the leap, the benefits of high-feed
milling can significantly outweigh the potential challenges. The
process offers amazing productivity, nearly triple the metal removal rate of conventional
methods, and increases tool life. However, there are several things you must know in order to
make high-feed milling successfully work for you.

1. Machine Tools
Rigid, highly capable machine tools are a must because the cutters run at high feeds, which
require the machine and the control to keep up with these demands. New equipment is a lot
more advantageous when dealing with high-feed milling technology. It’s possible to apply new
high-feed mills on older machines, but the process works best with large cutters because the
feeds and speeds are not as accelerated.

2. Inserts
Trigon-style inserts provide the lowest possible lead angle over round or square inserts. Low
lead angles produce a much thinner chip, which in turn, requires higher feedrates to maintain
proper chip thickness for the insert geometry. The lower lead angle also directs the cutting
forces in the axial direction, pushing up into the spindle, which is more stable and easier on
the machine. Higher lead angles create thicker chips requiring less adjustment in feedrate.
They also produce more radial force causing vibration and stress on the spindle bearings.

3. Insert Grade
Make sure you have the right insert grade for your job because you don’t want your tool to fail
prematurely, especially if you’re performing a lights-out operation. Choosing the correct insert
grade for the type of material you are machining can increase tool predictability, resulting in
fewer tool changes, less rejects and less reworking.

4. Machining Application
Not every machining method is created equal. While high-feed mills with long overhangs are
great, for high-speed options for milling processes, you need to remember you can’t run them
as fast as you would tools with shorter overhangs without adding specialized vibration
dampening toolholders or reducing cutting speed. When a tool with long overhang operates
faster than it should, you can experience increased vibrations, causing insert chipping and
premature insert failure.

5. Programming
Optimize the cutter path through proper programming, so you don’t put any unrealistic
demands on the cutting tool. For example, when you are in a mold and come to a corner,
changing directions without using a smooth transition is very hard on a tool because it creates
a large angle of engagement. A good rule of thumb is to program an arc that is 50 percent
larger than the cutter diameter. If using a 2.0” cutter, program a 3” diameter arc. Programming
an arc in pocket corners reduces the angle of engagement and avoids overloading the cutter.
Machine tools can also have problems in this area because several calculations are involved
in generating an arc. If the machine tool can’t properly calculate the arc, the toolpath can
become erratic.

6. Engaged Tools
Keep your high-feed mills as engaged as possible across the full diameter or less than half
the insert width. One of the reasons these mills work so well is because their cutting forces
are directed at the machine spindle in the axial direction to create balance. If you use the
same cutter and only engage it 50 or 60 percent of the diameter, you will experience push and
increased vibrations because the cut is unbalanced.

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5/8/2018 Six Points You Must Know about High-Feed Milling : MoldMaking Technology
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Article • High-feed milling is becoming the Product • Seco Tools Inc. (Troy, MI) offers a complete
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