SEMINAR ON

HIGH SPEED MACHINING

(HSM)

CONTENTS

Introduction
Definition of HSM
Advantages
Application areas
Machining system
Some recommended parameters
Comparison
Disadvantages
Conclusion

DEFINITION OF HSM
Carl Salomon assumes that
At a certain cutting speed
which is 5-10 times
higher than in
conventional machining
the chip removal
temperature at the cutting
edge will start to
decrease

DEFINITIONS

High cutting speed machining

High rotational speed machining
High feed machining
High speed and feed machining
High productive machining

Finally,
HSM is a powerful machining method that combines
high feed rates with high spindle speeds, specific
tools and specific tool motion.

ADVANTAGES

High material removal rate

High surface finish
Increased productivity
Possibility of machining of very thin walls
Reduction in lead times
Low cutting force
Cutting tool and work piece temperature are kept low
Connection time between the cutting edge and work piece is
short
It eliminates the need of coolant
Reduction of production process

FEATURES
Reduced heat
transfer in to the
work piece
Reduction of
cutting forces
Increased cutting
speed

EFFECTS
Part accuracy

Part accuracy
Surface quality
Stability of rotating
cutting tool feed rate
Increased material
removal

APPLICATION AREAS

Industry which deals with the machining of Al to

produce automotive components, small computer
parts or medical devices
Aircraft industry involves machining of Al often
with thin walls
Die mould industry which requires dealing with
finishing of hard materials .
Used to machine such parts as die casting dies,
forging dies, injection moulds and blow moulds,
milling of electrodes in graphite and copper,
modeling and prototyping of dies and moulds.

MACHINING SYSTEM
MACHINE TOOLS

3-axis horizontal and vertical milling machines

CNC 4-axis milling machine offers the option of
tilting the milling cutters to improve the cutting
conditions
5-axis machine with inter changeable spindle units
allow to rough, semi finish and finish with a single
set up.

DEMANDS ON THE MACHINE

Spindle speed range <=40000 rpm

Spindle power >22 KW
Programmable feed rate 40-60 m/min
Rapid travels <90 m/min
Block processing speed 1-20 ms
High thermal stability and rigidity in spindle
Air blast/coolant through spindle
Advanced look ahead function in the CNC

CUTTING TOOLS
1.

2.

3.

4.

5.

TiN and TiCN coated Carbide for materials with

hardness less than 42 HRC
TiALN coated Carbide for materials with hardness
42 HRC and above
For special applications like hard turning
(HRC 60-65) PCBN is used
Cubic boron nitrite (CBN) and ceramic for cast iron
Poly crystalline diamonds (PCD) and Cermets are
used for aluminum

RECOMMENDED PARAMETERS
1.True cutting speed
As the speed is dependent on both spindle speed
and diameter of tools HSM should be defined
as true cutting speed above a certain level

2.Material removal rate

Material removal rate,
Q = (ap* ae * vf)/1000 cm3/min
where ap = vertical dist from tool tip to the
reference point mm
ae = step over distance mm
vf = feed speed mm/min

3. Surface finish
Surface finish is depends upon cutting tool
geometry, coating of the cutting tool, wear
status of the cutting tool etc.

COMPARISONS
Conventional machine

High speed machine

Max speed 600 m/min

Speed starts at 600 m/min

Max feed ~40 ipm

Feed starts at 100 ipm

Require high levels

coolant

With coolant ,feed rate

can go more than 2000
ipm
No need for coolant for
low feed rate

Between conventional and high speed machines

Comparison between speeds used in conventional and high speed

machining

Conventional

HSM

The contact time between

tool and work is large

Contact time is short

Less accurate work piece

More accurate work piece

Cutting force is large

Cutting force is low

Low surface finish

High surface finish

Material removal rate is low

Material removal rate is

high

Cutting fluid is required

Cutting fluid is not required

Comparison between convl and HSM process

HSM

EDM

Material removal rate

high

Material removal rate is

low

Dimensional tolerance
0.02 mm

Dim tolerance
0.1- 0.2 mm
Cutting tool has to be
made according to the
contour to be machined

There is no need of
making cutting tool
according to the contour
to be machined

Comparison between HSM and EDM

DISADVANTAGES

Need for expensive and special machine tools

with advanced spindle and controllers
Excessive tool wear
Good work and process planning necessary
It can be difficult to find and recruit advanced
staff

CONCLUSIONS

HSM is not simply high cutting speed .It should be

regarded as a process where the operations are
performed with very specific methods and precision
equipment

HSM is not necessarily high spindle speed

machining. Many HSM applications are performed
with moderate spindle speeds and large sized cutters

HSM is performed in finishing in hardened steel with

high speeds and high feeds often with 4-6 times
conventional cutting speeds

HSM is high productive machining in small

sized components in roughing to finishing and
in finishing to super finishing in components
of all sizes.
Even though HSM is known for a long time,
the research are still being developed for
further improvement of quality and
optimization of cost.