This document discusses high speed machining (HSM). [1] HSM involves machining at spindle speeds above 15k RPM, requiring rigidity throughout the machine and thermal/feedback controls. [2] HSM allows finishing hardened materials and is now more common, having traditionally focused on dies/molds. [3] Compared to traditional machining, HSM uses advanced CAM toolpaths to dramatically increase parameters and reduce tooling wear, improving cycle times and profits.

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. 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

10. 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

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