Advanced Manufacturing [YI6777]

Advanced Cutting
High Speed Milling

Prof. Dr. Ir. Bert LAUWERS

Prof. Dr. Ir. Eleonora FERRARIS
Introduction

• Terminology
– HSC: High Speed Cutting
– HSM: High Speed Machining
– Hogesnelheidsfrezen – High Speed Milling

High speed machining 2

 Preliminary experimental campaign

• C. Salamon stated that by high cutting speed the

process temperature decreases instead of the opposite.
– Experiments conducted with big tools (big diameter to gain in
cutting speed, but the opposite, i.e. increasing of spindle rotation,
is better)
 d n
vc  [m / min]
1000

High speed machining 3

Temperature vs cutting speed diagram

High speed machining 4

Theory behind
• A full explanation of the
phenomena is not yet
available!

• According to the theory for

ductile cutting
– The system of forces on the
cutting plate (Fn and Fs) and
in the shear plane (F en FN)
require to be compensated in
overall
• Model of Hucks

: shear plane direction (angle)

  1
       arctan  s : Rake angle
µs: friction coefficient (between material
4 2 and cutting plate)

High speed machining 5

Theory behind

• Increasing of the cutting speed

leads to:
– High temperature -> decreasing of
the friction coefficient ->
increasing of the shear angle
(shear plane tilting)

– The ratio (hc/h) decreases -> smaller

cutting coefficient !

– Less shear energy necessary as a

consequence of the enlargement of hc
the shear angle.
• The temperature increasing remains h
limited
1 z
F  kc11 * b * h

High speed machining 6

Theory behind
1 z 1 z
F  kc11 * b * h  kc11 * a * f

High speed machining 7

Theory behind
• Cutting at high speed gives:
– Smaller forces
– Limited increasing of temperature of workpiece and tool
– Smaller thermal effected zone

• Because of the smaller cutting forces!

– Milling of aluminum for the creation of thin walls is a
possible application

• Feed rate as a function of feed per tooth (by milling) and

spindle rotation
– High cutting speed -> higher feed rare -> higher cutting power
• Example: Al High speed milling: endmill, Ø20mm, feed per tooth:
1/100, vc: 1000m/min, rpm: 32000t/min, feed rate: 6,4m/min
– For a given power -> depth of cut is usually limited

High speed machining 8

Selection of cutting speed as a function of the
material

Lichte legeringen

Gietijzer

Staal

Titaan legeringen

Superlegeringen

10 100 1.000 10.000

Snijsnelheid vc in m/min

Conventioneel verspanen Overgangsgebied Hoge-snelheidsverspanen

(br on : CETIM)

High speed machining 9

Machine with very high spindle rotation are
necessary!

High speed machining 10

Is it enough to use a classical machine with high
spindle speed?
• example
– http://www.ibagna.com/Videos/Ibag_Versi
on/iBAG_lo/iBAG_vid150.html

– By use of small diameter necessary to

achieve sufficien cutting speed

– By machining thin features (e.g. thin

walls) -> ok, overall forces are small
anyway

– But if productivity is the goal, you need

also high feed rate, and stability, and
power… a total new machine concept is
needed.

High speed machining 11

High speed milling technology

• It is not only a question of high speed spindle rotation

• A total concept as a combination of:

–High spindle rotation
–High feed rate
–Improved control
–Tool geometry and properties (coating for instance)
  further reduced friction  particularly important for HSC of hard materials
  even better resistance to high temperature!
–Lubrication
–Machine properties (stiffness, thermal stability,....)
–NC-programming, CAD/CAM (machining strategy,…)
–Workpiece material…..

High speed machining 12

HSC – a total concept!

Clamping
Clampingof
ofthe
theworkpiece
workpiece

Spindle
Spindle
machinestrcuture
machinestrcuture

• stiffness,
• damping Cutting
Cuttingtools
tools
Control
Control • dynamic aspects
• accuracy
•…..
technology
technology
motors
motors

Tool
Toolclamping
clamping

High speed machining 13

HSC – a total concept!
Overall process sketch

m a c h in e g e re e d sc h a p

h o o fd sp il b a sism a te ria a l
a a n d rijvin g a sse n g e o m e trie
C NC stu rin g d e kla a g
c o n stru c tie u itkra a g le n g te
g e re e d sc h a p so p n a m e
ve ilig h e id svo o rzie n in g
ko e lsyste e m
n a u wke u rig h e id
h o g e sn e lh e id sfre ze n

m a te ria a l C AD/C AM
vo rm sn ijp a ra m e te rs
o p sp a n n in g b e we rkin g sstra te g ie ë n

we rkstu k we rkvo o rb e re id in g

High speed machining 14

Tool material
• Important factors
– Core material, coating ,…
– Cutting tool geometry
– ….

– Concept
• To keep the friction
coefficient as small as
possible
• To increase the temperature
resistance as much as
possible

High speed machining 15

Tool material

6000m/min
(360km/u)

1000m/min

100m/min

10m/min

High speed machining 16

High feed rate

• Machine construction improvement is necessary -> only

recently new concept of faster and accurate machines
• e.g. via linear motors

High speed machining 17

Machine control

• High feed rate (but accuracy?)

– Test piece (e.g. according to
certain standard)

– Conditions
• Ball miill 10 mm diameter 2 tooth
• Spindle rotation 27000rpm
• ap: 0,5 mm
• ae: 0,3 mm
• Distance traveled: 284,05
mm (per pas)
• Number of passes: 33
• Response of interest
– Machining time => averaged feed
rate
– distance from the ideal profile

High speed machining 18

Machine control

• High feed rate is a must!

– Result: default settings

Programmed path
Tolerance limits
Measured profile

High speed machining 19

Machine control

• High feed rate is a must!

– Results
• Influence of the control parameter!
reële voedingssnelheid (mm/min)

10.000
9.000
8.000
7.000 default

6.000 P1
5.000
P2
4.000
3.000 P3
2.000
1.000
0

geprogrammeerde voedingssnelheid (mm/min)

High speed machining 20

Higher stiff machine and accuracy

• High feed rate  means higher acceleration  so higher

acceleration forces
– To avoid the movement of big workpiece (big mass)!
• In the case of big mass-> execute the operations on a machine
where all the movements are located on the tool (z axis)!
– The machines need to be sufficient stiff!
– Sufficient damping

High speed machining 21

HSC- machining strategy

• Machining of complex forms with ball mills

ae 2 ae2 ae 3
Rth  Rth  Opp 
8R 16R
R

High speed machining 22

HSC- machining strategy
• Machining of workpieces with thin walls
– Preference: “level first”  “depth first”

High speed machining 23

HSC- machining strategies
To avoid abrupt passages (this reduces the acceleration
forces)

• Spiral shapes
• Helicoidally entrance
• Minimisation of sharp edges
• Fluent movement

S-type overgangen

© UGS

High speed machining 24

Machining strategies

• Adaptation of the NC codes with respect to feed rate

– To accomplish constant cutting forces
• It is also better for the machine dynamics!

250 210 175

m m /m in m m /m in m m /m in

High speed machining 25

Machining strategies

• Adaptation of the NC codes with respect to feed rate

– All machiens have limitation-> use and development of special
programms! (bv. Programma OPTIMILL)

High speed machining 26

Applications
• Machining of aluminium
– Chip flow rate
– Milling of thin walls
• (smaller forces)

• Machining of other
materials
– Titanium, ….

High speed machining 27

Some research results

• HSC machine: MATSUURA FX-5G

– Max spindle rotation: 27.000 tr/min
– Workspace: 1.020 x 560 x 400
– Spindle power: 22.5 kW
– Torque (tot 1.250 tr/min): 46.8 Nm
– Torque (bij 27.000 tr/min): 7.2 Nm
– Feed rate: 30 m/min

High speed machining 28

HSC – milling of thin walls (Al)
• example

• Selection of the correct tool and

machining conditions of big
important to obtain a good
surface quality and dimensional
accuracy
High speed machining 29
HSC – milling of thin walls (Al)
0.2mm
• Test piece
– Aluminium, thickness 0.2 mm, hight 35 mm
• Tool

35 mm
– Hard metal with filled radius
– 2-tooths
– Diameter 12 mm
– radius 2 mm

0.2mm
• Verspaningscondities
1 2
– Toerental n = 27000 tr/min 3 10 mm
4
– Voeding fz = 0.1 mm/tand/tr 5

35 mm
6
– Snedediepte ap = 0.1 mm 7
8
– Snedebreedte ae = 4.8 mm 9
10
– Tegenlopend frezen 11
12

High speed machining 30

HSC – milling of thin walls (Al)
• End mills Ø 3 mm, 25 mm deep
– ap=0.4 mm, ae= 3mm, n = 22000 tr/min, 2 of 3.5 mm
fz= 0.03 mm per tooth, vf= 1300 mm/min,
z=2
– Rough machining tot 3 mm
finishing tot 3.5mm 60 mm

• End mills Ø 1.5 mm, 15 mm deep

– ap=0.12 mm, ae= 1.5mm, n = 27000 tr/min
(max. machine), fz= 0.015 mm/ per tooth,
vf= 810 mm/min, z=2
– Rough machining 1.5mm
finishing tor 2mm

High speed machining 31

 HSC – dynamic aspects
• chattering
– Stability region also depends
on the machine stiffness

dh dF
storing
+
Gm
-

Gp

High speed machining 32

HSC – dynamic aspect

• Vibration take place because of

– Impact of the mill tooth
– Inhomogeneity of the workpiece material
– Unbalance of the cutting tool (milling)
– …
• Dependently form the whole system dynamic (tool-
machine workpiece) vibration can be self-excited
vibration: chattering

High speed machining 33

HSC – dynamic aspects

• Wat is visible on these

pictures
– Cutting marks because of the feed
– Extra cutting marks because of
chattering
• Chatter consequences
– Limited life time of the cutting tool
– Low surface quality
– Dimensional accuracy
– Spindle wear, tool clamping wear
– noise

High speed machining 34

HSC – Dynamic Aspects

• Stability curve

Onstabiele zone
Snedediepte ap [mm]

eem ine ap
yst a ch dsch
n s •M ree k
r éé •Ge rkstu
o We eratie
ig vo •
•Op
eld
G Stabiele zone

Toerental n [tr/min]

High speed machining 35

HSC – dynamic aspects
• Tool holder clamping and
tools
– ISO conus
• Old model

– HSK
• Especially
suitable for HSC

High speed machining 36

HSC – dynamic aspects Tool: HM end-mill
Diameter 10 mm
number of tooth z = 2
• influence of tool clamping on unclamped tool length l = 36.8 mm
trilling
Work piece material: Aluminium

12

Snedediepte ap [mm]
10
onstabiel
8

2
stabiel
0

Toerental n [tr/min]

Spantang Krimp Hydrodehn

High speed machining 37

HSC – dynamic aspects

• influence of tool clamping on various aspects:

concentricity, unbalancing, clamping forces and stability

Concentricteit Onbalans Klemkracht Stabiliteit

(slag) (G2,5)

Spantanghouder ++ +++ ++ ++

Hydrodehn + + + +++

Krimphouder +++ +++ +++ +

Opmerking: “onbalans” is momentopname

High speed machining 38

HSC - dynamic aspects

• Influence of unclamped tool length

– Tool
• HM end-mill
– Diameter 10 mm
– Number of tooth z = 2

38.2 mm
– Work piece material: Aluminium

Stabiliteitscurve experimenteel

8
7
Snedediepte [mm]

6
5
4
3
2
1
0

52.4 mm
20000 21000 22000 23000 24000 25000 26000 27000
Toerental [tr\min]

Uitsteeklengte 52.4 mm Uitsteeklengte 38.2 mm

High speed machining 39

HSC - dynamische aspecten

• Influence of unclamped tool length (other machine –

HERMLE)
– tool
– HM end-mill
– Diameter 10 mm
– Number of tooth z = 2

Max spindle rotation: 15.000 tr/min

Workpieces domain: 800 x 600 x 500
Power at the spindle: 15 kW
torque(bij 1100 tr/min): 130 Nm
Feed rate: 30 m/min

High speed machining 40

HSC – dynamic aspects

• Influence of unclamped tool length (other machine –

HERMLE}

Courbe de stabilitéHermle
Stabiliteitscurve Hermle
n = 1000 rev/min
Longueur de l'outil =
Uitsteeklengte = 34 mm34 mm ap = 1 mm
de passe

13
12
11
10
9
Snedediepte
[mm]

8
7
Profondeur
[mm]

6
ap

5
4
3
2
1
0
4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000

Vitesse de rotation
Toerental n [rev/min]
n [tr/min]

High speed machining 41

HSC - dynamic aspects

• Influence of unclamped tool length (HERMLE)

Courbe de stabilitéHermle
Stabiliteitscurve Hermle n = 1000 rev/min
Longueur de l'outil
Uitsteeklengte = 45= 45mm
mm ap = 1 mm
ap [mm]

10
9
[mm]

8
de passe

7
Snedediepte

6
5
4
Profondeur

3
2
1
0
5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
Vitesse de rotation
Toerental n [tr/min]
n [tr/min]

High speed machining 42

HSC - dynamische aspecten

• Influence of unclamped tool length (HERMLE)

Courbe de stabilitéHermle
Stabiliteitscurve Hermle n = 1000 rev/min
Longueur de l'outil
Uitsteeklengte = 55= 55mm
mm ap = 1 mm
ap [mm]

8
7
[mm]

6
de passe

5
Snedediepte

4
Profondeur

3
2
1
0
5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
Vitesse de rotation
Toerental n [tr/min]
n [tr/min]

High speed machining 43