High Speed Machining - Industrial Engineering and Productivity Aspects

Lesson  of Industrial Engineering ONLINE Course.

High Speed Machining Using Makino MC1516 at Raytheon

Case 64 - Industrial Engineering ONLINE Course.

High speed machining is use of higher spindle speed of more than 20000 rpm and higher feed rates compared to conventional machining and material removal is carried out using small size cutting tools by giving faster and lighter cuts.

High Speed Machining (HSM) - High Efficiency Milling (HEM)

There were advancements in the metalworking industry that resulted in  new, innovative ways of increasing productivity.

High Speed Machining

High speed machining is  an umbrella term for all high productivity machining methods. In HSM, a very high spindle speed paired with much lighter axial depths of cut results in a much higher allowable feed rate. This is also often referred to as feed milling. Depths of cut involve a very low axial and high radial components.

High Efficiency Milling

Many new, high-productivity toolpaths were discovered or invented.. Terms like trochoidal milling,  adaptive milling, feed milling, and High Efficiency Milling are a handful of the names given to these cutting-edge techniques.

HEM has evolved from a philosophy that takes advantage of the maximum amount of work that a tool can perform. Considerations for chip thinning and feed rate adjustment are used so that each cutting edge of a tool takes a consistent chip thickness with each rotation, even at varying radial depths of cut and while interpolating around curves. This allows machinists the opportunity to utilize a radial depth of cut that more effectively uses the full potential of a given tool. Utilizing the entire available length of cut allows tool wear to be spread over a greater area, prolonging tool life and lowering production costs. Effectively, HEM uses small depths of cut used in  traditional finishing operation but boosts speeds and feeds, resulting in much higher material removal rates (MRR) in roughing applications.

Both HSM and HEM can achieve increased MRR and higher productivity when compared to traditional methods. While HSM is an umbrella term for all high efficiency cutting methods,  HEM is now considered as distinct from HSM.
https://www.harveyperformance.com/in-the-loupe/high-efficiency-milling-vs-high-speed-machining/

Incrementally Improving to High Speed

In general, 8,000 rpm is considered a minimum  for the rotational aspect of high speed machining.

Auxiliary spindles may be  used to do high speed machining. For a reasonable amount of money, installing an auxiliary high speed spindle on an existing machine is possible. The original machine tool spindle is kept as it is and additional spindle is simply bolt-on for high rpm capacity.

There is another secondary spindle option It is termed a fixed center line auxiliary spindle. Speeds for these units go up to 50,000 rpm, and up to 17 hp is available on some models. The unit mounts in the machine tool spindle but has its own power source and control. Because it operates off the same center line as the main spindle, programming is transferable with only the need to adjust Z-axis depths to compensate for the addition of the unit in the main spindle. 

https://www.makino.com/resources/content-library/article/archive/ramping-up-to-high-speed-machining/204

July 2010
https://www.ctemag.com/news/articles/what-high-speed-machining

High Speed Machining Case Studies
https://www.mmsonline.com/zones/browse/hsm/9

Sections in Stephenson - Agapiou Book

1. Introduction
2. High Throughput Machining
3. High Speed Machining
4. Tooling and Fixturing
5. Materials Handling Systems

2008

https://www.sme.org/technologies/articles/2008/high-speed-machining-for-aerospace/

Categorize aircraft parts into two broad categories of ‘thin-plate’ and ‘thick-plate’. What defines HSM for parts up to 50-mm thick are spindle rotations of 30,000 rpm and spindle ratings to 80 hp (60 kW). High speed for thick plates (greater than 50 mm thick) is 18,000 rpm and spindle ratings to 135 hp (100 kW).  “For either, acceleration/deceleration should be about 0.5 g, and you should offer as rapid a [noncutting] traverse as possible, at least 1500 ipm [38 m/min].” The acceleration/deceleration (acc/dec) significantly influences the cutting time in complicated pocketed parts, where the tool has to make many direction changes.

The MAG Cincinnati HyperMach profiler offers  a spindle speed of 24,000 rpm with 4000 ipm (101 m/min) rapid traverses. The traverse time affects cutting time, within that especially ‘parasitic’ time, which can be as high as 20% of total cycle time in cutting aluminum. Parasitic time includes positioning the tool for a new cut or moving to a tool changer.  HyperMach Vertical series of profilers  have a rapid-traverse rate of 4000 ipm [101 m/min].  

High-Speed Machining

1st Edition
Editors: Kapil Gupta J. Paulo Davim
Academic Press
Published Date: 4th February 2020
Page Count: 318


Preface
Chapter 1. Introduction to high-speed machining (HSM)
Chapter 2. Performance of Sialon/Si3N4 graded ceramic tools at high speed machining
Chapter 3. High speed machining of composite materials
Chapter 4. Advances in cooling and lubrication for high speed machining
Chapter 5. Cooling and machining strategies for high speed milling of titanium and nickel super alloys
Chapter 6. Virtual CNC machine tool modeling and machining simulation in high speed milling
Chapter 7. Modeling and analysis of high speed milling process stability for industry applications
Chapter 8. Cryogenic cooling-based sustainable machining
Chapter 9. Laser-assisted high speed machining of Inconel 718 alloy
Chapter 10. High speed machining of magnesium and its alloys
Chapter 11. Variants of high speed machining
Index
https://www.elsevier.com/books/high-speed-machining/gupta/978-0-12-815020-7

Chapter 1 - Introduction to high-speed machining (HSM)
Ankit Jain Vivek Bajpai
https://www.sciencedirect.com/science/article/pii/B9780128150207000011
Ch-2. https://www.sciencedirect.com/science/article/pii/B9780128150207000023 see for details of more chapters

Oct 2019
High speed machining is use of higher spindle speed of more than 20000 rpm and higher feed rates compared to conventional machining and material removal is carried out using small size cutting tools by giving faster and lighter cuts.
https://www.manufacturingtodayindia.com/sectors/5187-machine-matters-for-high-speed-machining

CUTTING TOOLS -  EFFECTIVE APPROACH TO HIGH-SPEED MACHINING
 May 27, 2019
https://www.industr.com/en/effective-approach-to-high-speed-machining-2376475

Thread: High speed machining aluminum... An open discussion.
2018
https://www.practicalmachinist.com/vb/cnc-machining/high-speed-machining-aluminum-open-discussion-363234/

https://hsmadvisor.com/

Cimskil — High Throughput Manufacturing

DOD Contract Award - High Throughput Manufacturing Manufacturing Programs.
We were awarded Phase III of the DOD High Throughput Manufacturing Program for automation of manufacturing processes for titanium parts.

This contract, valued at $700,000.00 to our company, after cost-sharing with the Department of Defense, follows on from the Hithru Program Phases I and II.

Hithru Phases I and II addressed two major areas:

Automation of manufacturing engineering tasks for machining 5-axis aerospace parts, based upon the recognition of manufacturing features on the as-designed part with subsequent automated processing of all work required to produce the first good part. Implementation of a means for end-users to easily program their manufacturing practices for use in automated processing. For details of the highly encouraging results of Hithru to date, please see Hithru Program.

Team Members for Phases I and II, who were also in Phase III:

National Center for Manufacturing Sciences (Program Management)
Warner Robins Air Logistics Center
Sikorsky Aircraft
Cincinnati Machine
Technology Answers
It is appropriate here to record our thanks to the team members who provided us with so much advice and guidance - and criticism when necessary!

New Team Members for Phase III were:

Boeing Defense & Space
Naval Aviation Depot, Cherry Point
Project Objectives for Phase III

The objective of HITHRU phase III is to develop and capture in CimskilTM best manufacturing practices for titanium components, and apply that knowledge to productivity improvement.

Titanium machining is more complex than aluminum machining. The material is much harder, making the selection of tools, inserts, and coatings a critical factor in determining machining parameters such as axial and radial depth of cut, feed rate and spindle RPM. It is also more expensive than aluminum, resulting in a greater need for efficiency in shop cutting tests. Titanium components with long machining cycles, for a given feature, will require a tool change (to overcome tool dulling) before the feature is completed. That means that the machining system must compensate for any inaccuracy introduced via a tool change. The issue is further complicated by the fact that program participants use a mixture of slab and forging stocks. Slab stock can use the fixturing methods developed in HITHRU phase I, but forging stock will require new fixturing strategies.

http://www.cimskil.com/News.htm



Innovations in Advanced Manufacturing - Papers of Seminars
NIST, USA - 2009
http://www.nist.gov/el/upload/whitepapers.pdf

Guide to Hard Milling and High Speed Machining
Dale Mickelson
Industrial Press, Oct 11, 2006 - 400 pages
https://books.google.co.in/books?id=88OjBgAAQBAJ

News Related to High Speed Machining

2021

High-Speed Machining of Malleable Cast Iron by Various Cutting Tools Coated by Physical Vapor Deposition

Suyang Li, Haisheng Lin, Tingjie Zhang, Jianbo Sui & Chengyong Wang 

Chinese Journal of Mechanical Engineering volume 34, Article number: 46 (2021)

https://cjme.springeropen.com/articles/10.1186/s10033-021-00561-8

Cylindrical turning experiments were performed on a CAK3665NJ NC lathe made by China Shenyang Machine Tool CNC Co., Ltd.

The cutting parameters of MCI were constant and set to v =150 m/min, f = 0.15 mm/rev and ap = 0.9 mm. 

The nc-TiAlSiN coated tool minimized the cutting force, specific cutting energy, surface roughness, and tool wear, and maximized the tool life. Therefore, the nc-TiAlSiN coated tool is the best choice for dry cutting of MCI.

HIGH SPEED MILLING

Our most recent purchase is a high speed  machining center – type GF Mill600S.

High speed milling centers are 10 times faster than conventional milling machines in terms of cutting speed. Greater accuracy and a better surface finish are also achieved.

https://www.hsieben.at/en/high-speed-milling/

Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

Nguyen, N.-T., Tien, D. H., Tung, N. T., & Luan, N. D. (2021). Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061. EUREKA: Physics and Engineering, (3), 71-84.

https://journal.eu-jr.eu/engineering/article/view/1824

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters.

2020

High-Speed Machining of Large Aluminum and Composite Parts

posted on DECEMBER 2, 2020

https://massesales.com/dec-9-2020-high-speed-machining-of-large-aluminum-and-composite-parts/

Multi-objective optimization of high-speed end milling on Al6061/ 3% RHA/ 6% TiC reinforced hybrid composite using Taguchi coupled GRA

2020 International Conference on Computational Intelligence for Smart Power System and Sustainable Energy (CISPSSE)

Date of Conference: 29-31 July 2020

https://ieeexplore.ieee.org/document/9212295

Finite Element Analysis and Parameter Optimization Selection of High Speed Milling GH4169

Guosheng Geng, Liang Zhang, Maohua Xiao, Xiayun Dong, Kailin Chen

College of Engineering, Nanjing Agricultural University, No.40, Dianjiangtai Road, Pukou Distinct, Nanjing 210031. China

Manufacturing Technology 2020, 20(3):300-306 | DOI: 10.21062/mft.2020.054

https://www.journalmt.com/artkey/mft-202003-0001_finite-element-analysis-and-parameter-optimization-selection-of-high-speed-milling-gh4169.php

We used ABAQUS finite element analysis software to simulate the 3D milling of GH4169 nickel base superalloy. The variation of milling force during milling was studied. The influences of milling speed, feed per tooth and radial depth on milling force were analyzed and the results of the simulation were compared with those obtained by orthogonal experiment. The variation of milling force was verified. Finally, we obtained the reasonable milling parameters.

High Speed Machining Cuts Moldmaking Cycle Time
15,000 rpm
http://www.mmsonline.com/articles/high-speed-machining-cuts-moldmaking-cycle-time



Patent 2014 - High Performance Milling

https://patents.google.com/patent/US8880212