Successfully reported this slideshow.

High speed machining imts 2012

860 views

Published on

Published in: Business
  • Be the first to comment

  • Be the first to like this

High speed machining imts 2012

  1. 1. High Speed Machining Time is money…
  2. 2. What is it? Usually associated with any spindle speed above 15k More than just a fast spindle The whole machine must be considered
  3. 3. Important Factors Casting and base rigidity Thermal growth control Axis position feedback Tool retention
  4. 4. Breaking Tradition Finish machining hardened materials has historically been EDM HSM traditionally focused on the die mold industry More prevalent today
  5. 5. Who uses HSM?The application of HSM often requires a substantial upfrontinvestment: – suitable machine tool, specially designed tooling, andan advanced CAM system.Aluminum & Composites Die General Production Aerospace Casting Dies Excessive Roughing Automotive Components Forging Dies Mid to High Production Small Computer Parts Injection Molds Excessive Rouging Ops Medical Devices Electrodes Thin Walled Parts Modeling & Prototyping Finishing Hard Materials
  6. 6. Advanced CAM Toolpaths Produces a consistent chip load and tool engagement – especially in corners Allowing for dramatically increased parameters Small diameter tooling can also be pushed far beyond traditional limits
  7. 7. Traditional Process vs. HSM Traditional Processing “Racetrack” toolpath patterns resulting in sharp corners Cutting parameters limited due to the increased linearMaterial 1018 CRS forces against the toolTooling 3/8” (9.5mm) Solid Carbide 3 Flute EndmillSpindle Speed 4,500 RPMDepth of Cut .25” (6.35mm) Intermittent over-Feedrate 30” ipm (762 mmpm) engagement caused extremeChip Load .002” (.050mm) tool wearCycle Run Time 11 Minutes, 16 Seconds
  8. 8. Traditional Process vs. HSM HSM Processing Much different toolpath pattern – NO sharp corners DOC, Feedrates, and RPM dramatically increasedMaterial 1018 CRSTooling 3/8” (9.5mm) Solid Carbide 3 Flute Endmill No noticeable wear on theSpindle Speed 12,000 RPM tool – tool will last thruDepth of Cut .625” (15.875mm) …FULL DEPTHFeedrate 157 – 285 ipm (3987 – 7238 mmpm) several partsChip Thickness .0033” (.0838mm)Cycle Run Time 2 Minutes, 51 Seconds
  9. 9. Standard Spindle - 12,000 RPM Same HSM processingMaterial 1018 CRS strategy, depth of cut, chipTooling 3/8” (9.5mm) Solid Carbide 3 Flute Endmill thickness, and toolingSpindle Speed 12,000 RPMDepth of Cut .625” (15.875mm) …FULL DEPTHFeedrate 157 – 285 ipm (3987 – 7238 mmpm) 33% faster spindle –Chip Thickness .0033” (.0838mm)Cycle Run Time 2 Minutes, 51 Seconds feedrates can be increased 18k = 33% FasterSpindle Speed 18,000 RPM Depending on geometry,Cycle Run Time 1 Minute, 54 Seconds UltiMotion could be even faster
  10. 10. Show me the money Traditional Processing High Speed Machining High Speed Machining (12K) (12K) (18K)Hourly Shop Rate $60.00 $60.00 $60.00Hourly Burden Rate $35.00 $35.00 $35.00Cycle Time 11 min : 16 sec 2 min : 51 sec 1 min : 54 secCost to Produce $6.57 $1.67 $1.11Quoted Price $13.50 $13.50 $13.50Profit per Part $6.93 $11.83 $12.39Profit x 100 pieces $693.00 $1,183.00 $1,239.00Profit x 500 pieces $3,465.00 $5,915.00 $6,195.00
  11. 11. UltiMotion Dynamic Variable Look Ahead – up to 10,000 blocks UltiMotion is predictive – controls velocity and acceleration based on upcoming obstacles Guarantees look ahead is always adequate enough for upcoming maneuvers
  12. 12. UltiMotion Exact same HSM program 29% cycle time reduction Improved surface finish qualityUltiMotion Standard Motion

×