High-speed machining (HSM) involves spindle speeds above 15,000 RPM and focuses on enhancing overall machine performance through factors like rigidity and thermal control. It requires significant investment in specialized tools and offers advantages such as reduced cycle times and increased efficiency compared to traditional machining methods. HSM is increasingly used in various industries, including aerospace, automotive, and medical devices, yielding substantial profits per part due to lower production costs.

1. High Speed Machining
Time is money…

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. Important Factors
 Casting and base
rigidity
 Thermal growth control
 Axis position feedback
 Tool retention

4. Breaking Tradition
 Finish machining hardened
materials has historically
been EDM
 HSM traditionally focused on
the die mold industry
 More prevalent today

5. Who uses HSM?
The application of HSM often requires a substantial upfront investment:
– suitable machine tool, specially designed tooling, and an 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. 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. Traditional Process vs. HSM
Traditional Processing
 “Racetrack” toolpath
patterns resulting in sharp
corners
 Cutting parameters limited
due to the increased linear
Material 1018 CRS forces against the tool
Tooling 3/8” (9.5mm) Solid Carbide 3 Flute Endmill
Spindle Speed 4,500 RPM
Depth of Cut .25” (6.35mm)  Intermittent over-
Feedrate 30” ipm (762 mmpm) engagement caused extreme
Chip Load .002” (.050mm)
tool wear
Cycle Run Time 11 Minutes, 16 Seconds

8. Traditional Process vs. HSM
HSM Processing
 Much different toolpath
pattern – NO sharp corners
 DOC, Feedrates, and RPM
dramatically increased
Material 1018 CRS
Tooling 3/8” (9.5mm) Solid Carbide 3 Flute Endmill  No noticeable wear on the
Spindle Speed 12,000 RPM
tool – tool will last thru
Depth of Cut .625” (15.875mm) …FULL DEPTH
Feedrate 157 – 285 ipm (3987 – 7238 mmpm)
several parts
Chip Thickness .0033” (.0838mm)
Cycle Run Time 2 Minutes, 51 Seconds

9. Traditional Process vs. HSM
Traditional Process High Speed Machining
11:16 2:51

10. Standard Spindle - 12,000 RPM
 Same HSM processing
Material 1018 CRS strategy, depth of cut, chip
Tooling 3/8” (9.5mm) Solid Carbide 3 Flute Endmill
thickness, and tooling
Spindle Speed 12,000 RPM
Depth of Cut .625” (15.875mm) …FULL DEPTH
Feedrate 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% Faster
Spindle Speed 18,000 RPM
 Depending on geometry,
Cycle Run Time 1 Minute, 54 Seconds UltiMotion could be even
faster

11. Show me the money
Traditional Processing High Speed Machining High Speed Machining
(12K) (12K) (18K)
Hourly Shop Rate $60.00 $60.00 $60.00
Hourly Burden Rate $35.00 $35.00 $35.00
Cycle Time 11 min : 16 sec 2 min : 51 sec 1 min : 54 sec
Cost to Produce $6.57 $1.67 $1.11
Quoted Price $13.50 $13.50 $13.50
Profit per Part $6.93 $11.83 $12.39
Profit x 100 pieces $693.00 $1,183.00 $1,239.00
Profit x 500 pieces $3,465.00 $5,915.00 $6,195.00

12. 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

13. UltiMotion
 Exact same
HSM program
 29% cycle
time reduction
 Improved
surface finish
quality
UltiMotion Standard Motion