Contents

1. High Speed Machining (HSM)--- Defined

2. Potential of HSM

3. The requirement of HSM

4. Cutting tool considerations

5. HSM processes

6. Some applications of HSM

7. Advantages & Limitations of HSM

1
 High Speed Machining

Introduction
A mean of using technology to process materials using higher
feed rates and higher RPM to provide a more efficient
method of tooling.

Machining with high speeds (HSM) is one of the modern

technologies, which in comparison with conventional cutting
enables to increase efficiency, accuracy and quality of
workpieces and at the same time to decrease costs and
machining time
 High Speed Machining--Defined
The first definition of HSM was proposed by Carl Salomon in
1931. He assumed that At a certain cutting speed which is 5-10
times than in conventional machining.

As a general guide, an approximate range of cutting speed may

be defined as fellows

„High speed: 600-1800m/min

„Very High speed: 1800-18000m/min

„Ultra High speed: >18000m/min

 High Speed Machining
What is it?
 Very high tool rpm, small
depths of cut and high feed
rates.

 High speed spindles are

required to match the process.(
Mainly used cutting tools are
ball nose end mills, flat end
mills and toric end mills from
solid carbide.)

4
 Requirements of HSM
 The following are important machine factors in high- speed
operations:
1. Power and stiffness of the machine tools,
2. Stiffness of tool holders and workholding devices,
3. Spindle design for high power and high rotational speeds,
4. Inertia of the machine-tool components,
5. Fast feed drives,
6. Level of automation, and
7. Selection of an appropriate cutting tool
 Cutting Tool consideration

 According to the formulated laws of product creation efficient

cutting of metal takes place only at times, when the cutting
material in cutting process temperature and conditions keeps
significant hardness superiority over the machined material.

 Much of the chip formation mechanics at high speed involve

heat. At high speed, which is relative to the material being cut,
higher heat is generated. More energy is going into the
workpiece and that energy becomes heat.
 Cutting Tool consideration (contd..)

 Higher temperature at the primary shear zone helps speed

up the plastic deformation process that results in a chip
being formed.

 Because of the increased rate of plastic flow, high speed

cutting experiences a decrease in the cutting force
with decreased cross section area of shaving needed to
remove a chip.
 Researchers estimate the heat input
distribution

1. About 80 percent of heat is generated by the

mechanical deformation that creates the chip,
2. 18 percent is created at the chip/tool interface .
3. 2 percent is created on the tool tip.
 Heat Estimate contd…

What goes in must come out. In the case of high speed

machining, heat generated in the cut is dissipated three ways:

1. About 75 percent is taken by the chip,

2. 5 percent by the workpiece, and
3. 20 percent is conducted through the tool
 APPLICATIONS OF HSM

Applications of HSM seem to divide into three categories.

1. Aircraft industry in which long airframe structural

components are machined from large aluminum blocks. Much
metal removal is required, mostly by milling. The resulting
pieces are characterized by thin walls and large surface-to-
volume ratios, but they can be produced more quickly and are
more reliable than assemblies involving multiple components
and riveted joints
 APPLICATIONS OF HSM (contd..)

2. Machining of aluminum by multiple operations

To produce a variety of components for industries such as
automotive, computer, and medical. Multiple cutting
operations mean many tool changes as well as many
accelerations and decelerations of the tooling
 APPLICATIONS OF HSM (contd..)

3. Die and mold industry

which fabricates complex geometries from hard materials. In
this case, high-speed machining involves much metal removal to
create the mold or die cavity and finishing operations to achieve
fine surface finishes.
 Advantages of high speed machining

 Ability to machine components in the shortest possible

time (decrease machining time)
 Higher production
 the reduction in lead times.
 Increase efficiency and accuracy work pieces
 Improve quality of work pieces
 Maximizes overall productivity – fewer process steps,
faster machining
 Advantages of HSM (contd..)

 Low cutting forces

 Increase part precision and surface finish.
 Limitations of HSM

 Higher acceleration and deceleration rates, and spindle start and

stop result in faster wear of guide ways, ball screws and spindle
bearings, leading to higher maintenance costs.

 HSM also requires specific process knowledge, programming

equipment and interfaces for fast data transfer needed.
Consequently, find suitably trained staff can be difficult.
 Limitations of HSM (contd…)

 HSM can involve a considerable "trial and error" period. Good

work and process planning is necessary, along with significant
safety precautions and safety enclosing.

 Tools, adapters and screws need to be checked regularly for

fatigue cracks. Only tools with posted maximum spindle speed
can be used.