June 22, 2008
June 22, 2008
June 25, 2008
13.665.1 - 13.665.11
High Performance Machining: A Practical Approach to High- Speed Machining
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.
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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