The document provides an overview of high speed machining (HSM), including its history, definitions, process parameters, machine details, advantages/disadvantages, applications, and conclusions. It discusses how HSM uses high spindle speeds and feed rates with specific tools and tool motions. Key benefits of HSM include improved accuracy, efficiency, reduced machining times, and decreased costs compared to conventional machining. The document also compares HSM to conventional machining and EDM.

1. A Presentation on,
By
NIKHIL R

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. • 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. Solomon’s curve

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. Effect of cutting speed on cutting
force

7. Effect of cutting speed on specific cutting force
for aluminium 7050

8. Transition Range of HSM for different

9. HIGH SPEED
MACHINING
ACCURACY
EFFICIENCY
REDUCED
MACHINING TIME
QUALITY OF
WORKPIECES
DECREASED
COSTS
High Speed machining leads to -

10. Improvement of production when using HSM

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)

13. Comparision between Conventional Machining and High
Speed Machining

14. 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

15. 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

17. 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,

18. 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

19. Surface finish is depends upon cutting tool geometry,
coating of the cutting tool, wear status of the cutting
tool etc.
3) Surface Finish:-

21. 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.

22. Vertical High Speed Machining Mills

23. Specifications

24. Horizontal High Speed Machining Mills

25. Specifications

26. Machine tool requirements for HSM

27. 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

29. 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

30. • 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

31. Tool holder balancing problem:-

32. APPLICATIONS OF HSM

34. • 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

35. • 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.

36. 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