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High-speed milling
Saut Genc,
Robert W. Messler Jr and Gabriele
Department of Mechanical Engineering,
Aeronautical Engineering
＆
Mechanics;
Department
of
Materials
Science
＆
Engineering,
Rensselaer
Polytechnic
Institute, Troy, NY, USA
High-speed
machining
is
an
advanced
manufacturing
technology,
different
from
the
traditional
processing
methods.
The
spindle
speed,
cutting
feed
rate,
cutting
a
small
amount of units within the time of removal of
material has increased three to six
times.
With
high
efficiency,
high
precision
and
high
quality
surface
as
the
basic
characteristics
of
the
automobile
industry,
aerospace,
mold
manufacturing
and
instrumentation
industry,
such
as
access
to
a
wide
range
of
applications,
has
made
significant
economic
benefits,
is
the
contemporary
importance
of
advanced
manufacturing
technology.
For
a
long
time,
people
die
on
the
processing
has
been
using
a
grinding
or
milling
EDM
(EDM)
processing,
grinding,
polishing
methods.
Although the high hardness of the EDM
machine parts, but the lower the productivity
of
its
application
is
limited.
With
the
development
of
high-speed
processing
technology, used to replace high-speed
cutting, grinding and polishing process to die
processing
has
become
possible.
To
shorten
the
processing
cycle,
processing
and
reliable quality assurance, lower
processing costs.
1 One of the
advantages of high-speed machining
High-speed
machining
as
a
die-
efficient
manufacturing,
high-quality,
low
power
consumption in an
advanced manufacturing technology. In conventional
machining in
a
series
of
problems
has
plagued
by
high-
speed
machining
of
the
application
have
been resolved.
1.1
Increase
productivity
High-speed
cutting
of
the
spindle
speed,
feed
rate
compared
withtraditional
machining, in the nature of the leap,
the metal removal rate increased 30 percent to 40
percent, cutting force reduced by 30
percent, the cutting tool life increased by 70% .
Hardened
parts
can
be
processed,
a
fixture
in
many
parts
to
be
completed
rough,
semi-finishing and
fine,
and all other processes, the
complex can reach parts of the
1
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surface
quality
requirements,
thus
increasing
the
processing
productivity
and
competitiveness of products in the
market.
1.2
Improve
processing
accuracy
and
surface
quality
High-
speed
machines
generally
have
high
rigidity
and
precision,
and
other
characteristics,
processing, cutting the depth of small, fast and
feed, cutting force low,
the
workpiece
to
reduce
heat
distortion,
and
high
precision
machining,
surface
roughness
small.
Milling
will
be
no
high-speed
processing
and
milling
marks
the
surface
so
that
the
parts
greatly
enhance
the
quality
of
the
surface.
Processing
Aluminum when up Ra0.40.6um, pieces of
steel processing at up to Ra0.2 ~ 0.4um.
1.3
Cutting
reduce
the
heat
Because the main axis milling machine
high-speed rotation, cutting a shallow cutting,
and feed very quickly, and the blade
length of the workpiece contacts and contact time
is
very
short,
a
decrease
of
blades
and
parts
of
the
heat
conduction.
High-speed
cutting by dry milling or oil cooked up
absolute (mist) lubrication system, to avoid the
traditional processing tool in contact
with the workpiece and a lot of shortcomings to
ensure that the tool is
not
high temperature under the conditions
of work, extended
tool life.
1.4 This is conducive to
processing thin-walled parts
High-speed
cutting
of
small
cutting
force,
a
higher
degree
of
stability,
Machinable
with high-quality employees compared to
the company may be very good, but other
than
the
company's
employees
may
Suanbu
Le
outstanding
work
performance.
For
our China practice, we use the models
to determine the method of staff training needs
are simple and effective. This study
models can be an external object, it can also be a
combination of internal and external.
We must first clear strategy for the development
of
enterprises.
Through
the
internal
and
external
business
environment
and
organizational resources, such as
analysis, the future development of a clear
business
goals and operational
priorities. According to the business development
strategy can
be
compared
to
find
the
business
models,
through
a
comparative
analysis
of
the
finalization
of
business
models.
In
determining
business
models,
a,
is
the
understanding of its development
strategy, or its market share and market growth
rate,
2
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or the staff of the situation, and so
on, according to the companies to determine the
actual
situation.
As
enterprises
in
different
period
of
development,
its
focus
is
different,
which
means
that
enterprises
need
to
invest
the
manpower
and
financial
resources
the
focus
is
different.
So
in
a
certain
period
of
time,
enterprises
should
accurately selected their business
models compared with the departments and posts,
so more practical significance, because
the business models are not always good, but
to compare some aspects did not have
much practical significance, Furthermore This
can more fully concentrate on the
business use of limited resources. Identify
business
models, and then take the
enterprise of the corresponding departments and
staff with
the business models for
comparison, the two can be found in the
performance gap, a
comparative analysis
to find reasons, in accordance with this business
reality, the final
identification
of
training
needs.
The
cost
of
training
is
needed,
if
not
through
an
effective
way to determine
whether
companies need to
train
and the training of
the
way, but blind to training, such
training is difficult to achieve the desired
results. A
comparison only difference
between this model is simple and practical
training.
1.5
Can
be
part
of
some
alternative
technology,
such
as
EDM,
grinding
high
intensity and high
hardness processing
High-speed cutting
a major feature of high-speed cutting machine has
the hardness of
HRC60 parts. With the
use of coated carbide cutter mold processing,
directly
to the
installation
of
a
hardened
tool
steel
processing
forming,
effectively
avoid
the
installation of several
parts of the fixture error and improve the parts
of the geometric
location accuracy. In
the mold of traditional processing, heat treatment
hardening of
the workpiece required
EDM, high-speed machining replace the traditional
method of
cutting
the
processing,
manufacturing
process
possible
to
omit
die
in
EDM,
simplifying
the
processing
technology
and
investment
costs
.
High-speed milling in the precincts of
CNC machine tools, or for processing centre,
also in the installation of high-speed
spindle on the general machine tools. The latter
not only has the processing capacity of
general machine tools, but also for high-speed
milling,
a
decrease
of
investment
in
equipment,
machine
tools
increased
flexibility.
Cutting
high-speed
processing
can
improve
the
efficiency,
quality
improvement,
3
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streamline processes,
investment and machine tool investment and
maintenance costs
rise, but
comprehensive, can significantly increase economic
efficiency.
2 High-speed
milling
High-speed
milling
the
main
technical
high-speed
cutting
technology
is
cutting
the
development direction of one of it with
CNC technology, microelectronic technology,
new materials and new technology, such
as technology development to a higher level.
High-speed
machine
tools
and
high-
speed
tool
to
achieve
high-speed
cutting
is
the
prerequisite
and
basic
conditions,
in
high-speed
machining
in
the
performance
of
high-speed
machine
tool
material
of
choice
and
there
are
strict
requirements.
2.1 High-speed milling machine in order
to achieve high-speed machining
General use of highly flexible high-
speed CNC machine tools, machining centers, and
some
use
a
dedicated
high-speed
milling,
drilling.
At
the
same
time
a
high-speed
machine
tool
spindle
system
and
high-speed
feeding
system,
high
stiffness
of
the
main
characteristics
of
high-precision
targeting
and
high-precision
interpolation
functions,
especially high-precision arc interpolation
function. High-speed machining
systems
of the machine a higher demand, mainly in the
following areas:
General use of highly
flexible high-speed CNC machine tools, machining
centers, and
some
use
a
dedicated
high-
speed
milling,
drilling.
At
the
same
time
a
high-speed
machine
tool
spindle
system
and
high-speed
feeding
system,
high
stiffness
of
the
main
characteristics
of
high-precision
targeting
and
high-precision
interpolation
functions,
especially high-precision arc interpolation
function. High-speed machining
systems
of
the
machine
a
higher
demand,
mainly
in
the
following
areas:
High-speed
milling
machine
must
have
a
high-speed
spindle,
the
spindle
speed
is
generally 10000 ~ 10 0000 m / min,
power greater than 15 kW. But also with rapid
speed
or
in
designated
spots
fast-stopping
performance.
The
main
axial
space
not
more
than 0 .0 0 0 2 m
m. Often using high-
speed spindle-hydrostatic bearings, air
pressure-bearing,
mixed
ceramic
bearings,
magnetic
bearing
structure
of
the
form.
Spindle
cooling
general
use
within
the
water
or
air
cooled.
High-
speed processing machine-driven system should be
able to provide 40 ~ 60 m /
4
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min of the
feed rate, with good acceleration characteristics,
can provide 0.4 m/s2 to 10
m/s2
acceleration
and
deceleration.
In
order
to
obtain
good
processing
quality,
high-speed cutting
machines must have a high enough stiffness.
Machine bed material
used gray iron,
can also add a high-damping base of concrete, to
prevent cutting tool
chatter
affect
the
quality
of
processing.
A
high-speed
data
transfer
rate,
can
automatically
increase
slowdown.
Processing
technology
to
improve
the
processing
and cutting tool
life. At present high-speed machine tool
manufacturers, usually in the
general
machine tools on low speed, the feed of the rough
and then proceed to heat
treatment,
the
last
in
the
high-speed
machine
on
the
half-finished
and
finished,
in
improving the accuracy and efficiency
at the same time, as far as possible to reduce
processing Cost.
2.2 High-speed machining tool
High-speed
machining
tool
is
the
most
active
one
of
the
important
factors,
it
has
a
direct
impact
on
the
efficiency
of
processing,
manufacturing
costs
and
product
processing and accuracy. Tool in high-
speed processing to bear high temperature, high
pressure,
friction,
shock
and
vibration,
such
as
loading,
its
hardness
and
wear-resistance,
strength
and
toughness,
heat
resistance,
technology
and
economic
performance
of
the
basic
high-speed
processing
performance
is
the
key
One
of
the
factors.
High-speed cutting tool technology development
speed, the more applications
such as
diamond (PCD), cubic boron nitride (CBN), ceramic
knives, carbide coating,
(C)
titanium
nitride
Carbide
TIC
(N)
And
so
on.
CBN
has
high
hardness,
abrasion
resistance
and
the
extremely
good
thermal
conductivity,
and
iron
group
elements
between the great
inertia, in 1300
℃
would not have happened significant
role in the
chemical, also has a good
stability. The experiments show that with CBN
cutting tool
HRC35 ~ 67 hardness of
hardened steel can achieve very high speed.
Ceramics have
good wear resistance and
thermal chemical stability, its hardness,
toughness below the
CBN,
can
be
used
for
processing
hardness
of
HRC
<5
0
parts.
Carbide
Tool
good
wear
resistance, but the hardness than the low-CBN and
ceramics. Coating technology
used
knives,
cutting
tools
can
improve
hardness
and
cutting
the
rate,
for
cutting
HRC40
~ 50 in hardness between the workpiece. Can be
used to heat-resistant alloys,
5
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titanium
alloys, hightemperature alloy, cast iron,
Chungang, aluminum and composite
materials
of
high-speed
cutting
Cut,
the
most
widely
used.
Precision
machining
non-ferrous metals or non-metallic
materials, or the choice of polycrystalline
diamond
Gang-coated tool.
2.3
High-speed
processing
technology
High-speed cutting
technology for high-speed machining is the key.
Cutting Methods
misconduct, will
increase wear tool to less than high-speed
processing purposes. Only
high-speed
machine
tool
and
not
a
good
guide
technology,
high-speed
machining
equipment can not fully play its role.
In high-speed machining, should be chosen with
milling, when the milling cutter
involvement with the workpiece chip thickness as
the
greatest,
and
then
gradually
decreased.
High-speed
machining
suitable
for
shallow
depth
of cut, cutting depth of not more than 0.2 mm, to
avoid the location of deviation
tool to
ensure that the geometric precision machining
parts. Ensure that the workpiece
on
the
cutting
constant
load,
to
get
good
processing
quality.
Cutting
a
single
high-speed milling path-cutting mode,
try not to interrupt the process and cutting tool
path, reducing the involvement tool to
cut the number to be relatively stable cutting
process.
Tool
to
reduce
the
rapid
change
to,
in
other
words
when
the
NC
machine
tools must cease immediately, or
Jiangsu, and then implement the next step. As the
machine
tool
acceleration
restrictions,
easy
to
cause
a
waste
of
time,
and
exigency
stop or radical
move would damage the surface accuracy. In the
mold of high-speed
finishing, in each
Cut, cut to the workpiece, the feed should try to
change the direction
of a curve or arc
adapter, avoid a straight line adapter to maintain
the smooth process
of cutting.
3
Die
in
high-speed
milling
processing
of
Milling as a
highly efficient high-speed cutting of the new
method,in
Mould
Manufacturing has been widely used. Forging links
in the regular production
model, with
EDM cavity to be 12 ~ 15 h, electrodes produced 2
h. Milling after the
switch to high-
speed, high-speed milling cutter on the hardness
of HRC 6 0 hardened
tool
steel
processing.
The
forging
die
processing
only
3
h20min,
improve
work
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