High Speed Machining

LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY
Name: Syed Aqib Ahmed

Roll no.: 15M21A03Q0
Branch: Mechanical-C
Topic: High speed Machining
SEMINAR ON
HIGH SPEED MACHINING (HSM)

 Introduction
 Definitionof HSM
 Advantages
 Application areas
 Machining system
 Some recommended parameters
 Comparison
 Disadvantages
 Conclusion
CONTENTS
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”
 High cutting speed machining
 High rotational speed machining
 High feed machining
 High speed and feed machining
 High productive machining
DEFINITIONS
“HSM is a powerful machining method that combines high
feed rates with high spindle speeds, specific tools and
specific tool motion.”
FEATURES EFFECTS
Reduced heat Part accuracy

transfer in to the
work piece
Reduction of Part accuracy
cutting forces Surface quality
Increased cutting Stability of rotating
speed 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.
 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
DEMANDS ON THE MACHINE

CUTTING TOOLS
1. TiN and TiCN coated Carbide for materials with

hardness less than 42 HRC
2. TiALN coated Carbide for materials with hardness
42 HRC and above
3. For special applications like hard turning
(HRC 60-65) PCBN is used
4. Cubic boron nitrite (CBN) and ceramic for cast
iron
5. 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 With coolant ,feed rate
coolant can go more than 2000
ipm
No need for coolant for
low feed rate
Between conventional and high speed machines
Conventional HSM
The contact time between Contact time is short

tool and work is large
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

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
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.

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LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Name: Syed Aqib Ahmed

HIGH SPEED MACHINING (HSM)

Carl Salomon assumes that

Reduced heat Part accuracy

 Industry which deals with the machining of

 3-axis horizontal and vertical milling

DEMANDS ON THE MACHINE

1. TiN and TiCN coated Carbide for materials with

1.True cutting speed

As the speed is dependent on both spindle speed and diameter

Material removal rate,

Conventional machine High speed machine

The contact time between Contact time is short

Comparison between convl and HSM process

 High material removal rate

 Need for expensive and special machine tools with

 HSM is not simply high cutting speed .It should

 HSM is not necessarily high spindle speed

 HSM is performed in finishing in hardened

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