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High Performance Machining: A Practical Approach To High Speed Machining

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Conference

2008 Annual Conference & Exposition

Location

Pittsburgh, Pennsylvania

Publication Date

June 22, 2008

Start Date

June 22, 2008

End Date

June 25, 2008

ISSN

2153-5965

Conference Session

CAD/CAM in Manufacturing Education

Tagged Division

Manufacturing

Page Count

11

Page Numbers

13.665.1 - 13.665.11

Permanent URL

https://peer.asee.org/3816

Download Count

483

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Paper Authors

biography

Adrian Teo Arizona State University

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Adrian Teo is the owner and operator of Function7 Engineering, an aftermarket automotive parts supply company. He is both a Arizona State University staff member in the University Technology Office and a graduate student in the Mechanical and Manufacturing Engineering Technology Department, with an emphasis is CNC machining.

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Scott Danielson Arizona State University

biography

Trian Georgeou Arizona State University

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Trian Georgeou graduated from Arizona State University (ASU) in 2003 with a Bachelor of Science in Manufacturing Engineering Technology. He worked in industry as a Mechanical Engineer while attending graduate school, earning his Master of Science in Technology, concentration of Mechanical Engineering Technology in 2006. While in graduate school, Trian also taught as an adjunct faculty member in Chandler Gilbert Community College’s Automated Manufacturing Systems program. Trian worked in the aftermarket automotive industry as an engineering and design consultant for two major companies. Currently, he is a Lecturer in the ASU Mechanical & Manufacturing Engineering Technology Department while remaining active in the aftermarket automotive industry.

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Abstract
NOTE: The first page of text has been automatically extracted and included below in lieu of an abstract

High Performance Machining: A Practical Approach to High- Speed Machining

Abstract

High-speed machining (HSM) has become a popular topic in CNC machining methodology in recent years. Simply defined, high-speed machining is a methodology to improve machining throughput by using higher-than-normal spindle speeds coupled with extraordinarily high feed rates without compromising the quality of the finished part. However, in practice, HSM is not a straightforward methodology to implement. In addition to the higher spindle speeds, numerous other factors like feed, chip loading, width and depth of cut, cutter path, tooling, machine construction, CNC-machine controls and CAM software all impact the HSM process. Most conventional CNC machines are equipped with a spindle with lower rpm limits (under 12,000 rpm), so the term “high performance machining” is adopted (HPM). Applying HPM methodology requires the manufacturing engineer to possess in-depth knowledge of the limits of the CNC machine and how to work around them. An initial investment into discovering the limits of any CNC machine is critical to applying HSM techniques to non-specialized CNC machines to obtain high performance machining. This paper briefly addresses the basic concepts of HSM. Then a methodology taught at Arizona State University for systematically determining the high performance machining envelope for a CNC machine is described. A student- implemented case study of this methodology resulting in significant performance gains of machining an automotive part is presented.

Introduction

Current machining methodology is largely experience-based in that much of the knowledge has been handed-down from machinist to machinist via apprenticeships or on-the-job training. The traditional approach to machining often has problems solved by reducing the cutting speed and/or reducing the amount of material being cut1. This approach results in cutting parameters that are discovered through trial and error and are typically very conservative. Even when manufacturing education programs teach students to utilize references like Machinery’s Handbook3, machining parameters are somewhat conservative.

Arizona State University manufacturing faculty believe it is important that manufacturing engineers interested in machining understand high performance machining, particularly as applied to conventional machine tools. Thus, their program teaches this content to interested seniors and graduate students. Such knowledge enables manufacturers to improve throughput and increase competitiveness without a significant investment in new machine tools.

Typically, high-speed machining (HSM) is achieved by using small cut depths at very high spindle speeds (often over 20,000 RPM) and aggressive chip loads without a degragration of part accuracy or quality2. Maintaining a light cut depth allows for high feedrates while avoiding damage to the workpiece, spindle and cutter. A common pitfall common to first-time adopters of

Teo, A., & Danielson, S., & Georgeou, T. (2008, June), High Performance Machining: A Practical Approach To High Speed Machining Paper presented at 2008 Annual Conference & Exposition, Pittsburgh, Pennsylvania. https://peer.asee.org/3816

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