High Speed Machining | Hurco IMTS 2012
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High speed machining explained and how the new Hurco VMX-HSi line of machines helps you achieve this technique.
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High Speed Machining | Hurco IMTS 2012
- 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