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A Presentation on,
By
NIKHIL R
CONTENTS:-
• History of High speed machining
• Comparison between conventional and high speed
machining
• Process paramete...
• First tries were made in early twenties of the past
century.
• The first definition of HSM was proposed by Carl
Salomon ...
Solomon’s curve
DEFINITIONS
• High cutting speed machining (Vc)
• High spindle speed machining (n)
• High feed machining (f)
• High speed ...
Effect of cutting speed on cutting
force
Effect of cutting speed on specific cutting force
for aluminium 7050
Transition Range of HSM for different
HIGH SPEED
MACHINING
ACCURACY
EFFICIENCY
REDUCED
MACHINING TIME
QUALITY OF
WORKPIECES
DECREASED
COSTS
High Speed machining...
Improvement of production when using HSM
FEATURES EFFECTS
Reduced heat
transfer in to the
work piece
Part accuracy
Reduction of
cutting forces
Part accuracy
Surfac...
Comparision between Conventional Machining and High
Speed Machining
Conventional HSM
The contact time between
tool and work is large
Contact time is short
Less accurate work piece More accur...
HSM EDM
Material removal rate
high
Material removal rate is
low
Dimensional tolerance
0.02 mm
Dim tolerance
0.1- 0.2 mm
Th...
1) True cutting speed:-
• As cutting speed is dependent on
both
spindle speed and the diameter of the
tool, HSM should be ...
2) Metal Removal Rate
The metal removal rate is given by,
Where,
ap = vertical distance from tool tip to the reference poi...
Surface finish is depends upon cutting tool geometry,
coating of the cutting tool, wear status of the cutting
tool etc.
3)...
Machine tools available-
• 3-axis horizontal and vertical milling machines.
• CNC 4-axis milling machine offers the option...
Vertical High Speed Machining Mills
Specifications
Horizontal High Speed Machining Mills
Specifications
Machine tool requirements for HSM
1. TiN and TiCN coated Carbide for materials with
hardness less than 42 HRC
2. TiALN coated Carbide for materials with har...
ADVANTAGES
• High material removal rate
• High surface finish
• Increased productivity
• Possibility of machining of very ...
• Need for expensive and special machine tools
with advanced spindle and controllers
• Excessive tool wear
• Good work and...
Tool holder balancing problem:-
APPLICATIONS OF HSM
• HSM is not simply high cutting speed .It should be
regarded as a process where the operations are
performed with very sp...
• HSM is high productive machining in small
sized components in roughing to finishing and
in finishing to super finishing ...
The technical papers referred for this seminar are listed below.
[1] PASKO, R. - PRZYBYLSKI, L. & SLODKI, B, High Speed Ma...
High speed machining (HSM)
High speed machining (HSM)
High speed machining (HSM)
High speed machining (HSM)
High speed machining (HSM)
High speed machining (HSM)
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High speed machining (HSM)

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High speed machining (HSM)

  1. 1. A Presentation on, By NIKHIL R
  2. 2. CONTENTS:- • History of High speed machining • Comparison between conventional and high speed machining • Process parameters • Machine details • Advantages & Disadvantages • Application areas of HSM • Conclusion
  3. 3. • First tries were made in early twenties of the past century. • The first definition of HSM was proposed by Carl Salomon in 1931. • He has assumed that at a certain cutting speed which is 5 –10 times higher then in conventional machining, the chip tool interface temperature will start to decrease. HISTORY OF HSM:-
  4. 4. Solomon’s curve
  5. 5. DEFINITIONS • High cutting speed machining (Vc) • High spindle speed machining (n) • High feed machining (f) • 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.”
  6. 6. Effect of cutting speed on cutting force
  7. 7. Effect of cutting speed on specific cutting force for aluminium 7050
  8. 8. Transition Range of HSM for different
  9. 9. HIGH SPEED MACHINING ACCURACY EFFICIENCY REDUCED MACHINING TIME QUALITY OF WORKPIECES DECREASED COSTS High Speed machining leads to -
  10. 10. Improvement of production when using HSM
  11. 11. FEATURES EFFECTS Reduced heat transfer in to the work piece Part accuracy Reduction of cutting forces Part accuracy Surface quality Increased cutting speed Stability of rotating cutting tool & feed rate Increased material removal rate (MRR)
  12. 12. Comparision between Conventional Machining and High Speed Machining
  13. 13. 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 Poor surface finish Good surface finish Material removal rate is low Material removal rate is high Cutting fluid is required Cutting fluid is not required
  14. 14. HSM EDM Material removal rate high Material removal rate is low Dimensional tolerance 0.02 mm Dim tolerance 0.1- 0.2 mm There is no need of making cutting tool according to the contour to be machined Cutting tool has to be made according to the contour to be machined Comparision between EDM and HSM
  15. 15. 1) True cutting speed:- • As cutting speed is dependent on both spindle speed and the diameter of the tool, HSM should be defined as “true cutting speed“ above a certain level. Feed is given by,
  16. 16. 2) Metal Removal Rate The metal removal rate is given by, Where, ap = vertical distance from tool tip to the reference point mm ae = step over distance mm vf = feed speed mm/min
  17. 17. Surface finish is depends upon cutting tool geometry, coating of the cutting tool, wear status of the cutting tool etc. 3) Surface Finish:-
  18. 18. Machine tools available- • 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.
  19. 19. Vertical High Speed Machining Mills
  20. 20. Specifications
  21. 21. Horizontal High Speed Machining Mills
  22. 22. Specifications
  23. 23. Machine tool requirements for HSM
  24. 24. 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 CUTTING TOOLS
  25. 25. 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
  26. 26. • 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 DISADVANTAGES
  27. 27. Tool holder balancing problem:-
  28. 28. APPLICATIONS OF HSM
  29. 29. • 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 CONCLUSION
  30. 30. • 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.
  31. 31. The technical papers referred for this seminar are listed below. [1] PASKO, R. - PRZYBYLSKI, L. & SLODKI, B, High Speed Machining (HSM) – the effective way of modern cutting, Cracow University of Technology. [2] M.A. DAVIES, T. J. BURNS, T. L. SCHMITZ, High-Speed Machining Processes: Dynamics on Multiple Scales, National Institute of Standards and Technology, USA. [3] J. KOPAC, Advanced tool materials for high-speed machining, 12th international science conference paper, Faculty of Mechanical Engineering, University of Ljubljana, Slovenia. [4] HERBERT SCHULZ, The History of High-Speed Machining, Darmstadt University of Technology, Germany. REFERENCES

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