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Metal Cutting

High-Speed Machining 310

This class compares high-speed machining to traditional machining and explains the key factors that impact its successful application.

Difficulty Advanced
Format Online
Number of Lessons 20
Language English

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Objectives
What Is High-Speed Machining?
Advantages of HSM
The HSM Process
The Importance of Spindle Speed
Cutting Variables for HSM
Spindles for HSM
Spindle Bearings
Cutting Tool Selection
Cutting Material Selection
Toolholder Balancing
Toolholders for HSM
Chip Clearance Methods
Machine Tools for HSM
HSM and Die/Mold Making
HSM in the Aerospace Industry
Retrofitting an Older Machine Tool
Purchasing a New HSM Tool
Transitioning to HSM
Summary

Define HSM.
Identify the advantages of HSM.
Describe the HSM cutting process.
Identify the range of HSM spindle speeds.
Identify the range of HSM cutting variables.
Describe the relationship of torque and spindle speed.
Describe HSM spindle construction.
Identify tools appropriate for HSM.
Identify cutting tool materials for HSM.
Describe the impact of balanced toolholders in HSM.
Distinguish between V-flange and HSK toolholders.
Identify chip clearance methods for HSM.
Distinguish between ballscrews and linear motors.
Describe the advantages of HSM for die and mold making.
Describe the advantages of HSM for aerospace.
Describe the ways machine tools can be retrofit for HSM.
Describe the important design specs for an HSM machine tool.
Describe the requirements of moving to HSM.

Vocabulary Term

Definition

ballscrew

A long, threaded device with reciprocating ball bearings that rotates to move components on a CNC machine. Ballscrews are powered by servomotors.

bearing

The device within a spindle that supports the rotating shaft and reduces friction. Common bearings consist of spherical balls that travel within a race.

centrifugal force

A force that attempts to pull an object traveling in a cylindrical path away from the center of rotation.

cubic boron nitride

A type of cutting tool material offering a hardness that is second only to diamond. CBN tools are very effective at machining most steels and cast irons, but they are also very expensive.

direct drive motor

A motor that fits within the spindle assembly and directly powers spindle rotation. Direct drive motors do not use a gearbox.

EDM

Electrical Discharge Machining. EDM uses a rapid series of electrical sparks to vaporize and remove metal.

fixed centerline spindle

A secondary spindle with its own power source that fits into the original spindle of a machine tool. Both spindles rotate simultaneously to increase spindle speed.

high-speed machining

An approach to metal cutting using recent speed technology that allows machining centers to do more work. HSM uses small diameter tools to perform multiple, rapid, light cuts.

high-velocity machining

Another term used for high-speed machining. Some manufacturers prefer this term because it emphasizes other variables besides spindle speed.

HSK toolholder

A type of toolholder with a short, hollow taper that contacts the spindle on two surfaces. HSK toolholders provide improved rigidity during HSM operations.

hybrid bearing

A bearing that consists of ceramic balls that travel within a steel race.

hydrostatic bearing

A bearing that uses pressurized fluid to support the rotating shaft.

linear motor

A flat motor that uses a magnetic field instead of mechanical force to power the motion of machine tool components.

magnetic bearing

A bearing that uses magnetic forces to support the rotating shaft.

plastic deformation

Metal deformation that is permanent. During metal cutting, plastic deformation results from the forces that shear the chip from the workpiece surface.

polycrystalline diamond

The manufactured formation of diamond that has a hardness approaching natural diamond.

race

The track within a bearing that guides the motion of the balls.

rake angle

An angle describing the tilt of the face from the cutter axis or radius. Positive rake angles reduce cutting forces and encourage chip removal.

servomotor

A motor used in CNC machines that turns the ballscrew to move parts with precision.

shrink fitting

An assembly process that involves heating a component, fitting components together, and then cooling the component to create a tight fit.

spindle speed

The rate at which the machine spindle rotates. Spindle speed is typically measured in rpm.

TiAlN

Titanium aluminum nitride. TiAlN coatings help improve the wear resistance of carbide inserts at elevated temperatures.

torque

The ability of a machine to exert a torsional force at a particular speed. The torque of a machine will vary across its speed range.

V-flange toolholder

A type of toolholder with a long, conical taper that contacts the spindle only on the taper surface. V-flange toolholders are very popular for conventional machining processes.