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high speed machining
1. A
Seminar
On
“HIGH SPEED MACHINING”
Presented by
MR. Vaibhav V Chopade
Under the Guidance of
Prof. P. R. DABHADE
Department of Mechanical Engineering
Siddhivinayak Technical Campus, School of Polytechnic
& Research Technology Shegaon,
Dist- Buldhana – 444 203 (Maharashtra)
2017-18
2. CONTENTS
Introduction
Machining system
Demands on the machine
Application areas
Comparison
Advantages
Disadvantages
Conclusion
3. INTRODUCTION
High cutting speed machining
High rotational speed machining
High feed machining
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.”
4. MACHINING SYSTEM
MACHINE TOOLS
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.
5. CUTTING TOOLS
TiN and TiCN coated Carbide for
materials with hardness less than 42 HRC
TiALN coated Carbide for materials with
hardness 42 HRC and above
For special applications like hard turning
(HRC 60-65) PCBN is used
Cubic boron nitrite (CBN) and ceramic for
cast iron
Poly crystalline diamonds (PCD) and
Cermets are used for aluminum
6. Toolholder & Tool Unbalance
Problem
HSK
Dynamic vs. static
run-out.
Shrink fit
‘Tribos’
8. DEMANDS ON THE MACHINE
Spindle speed range <=40000 rpm
Spindle power >22 KW
Programmable feed rate 40-60 m/min
Rapid travels <90 m/min
Block processing speed 1-20 ms
High thermal stability and rigidity in spindle
Air blast/coolant through spindle
Advanced look ahead function in the CNC
9. 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
10. APPLICATION AREAS
Industry which deals with the
machining of Al to produce automotive
components, small computer parts or
medical devices
Aircraft industry involves machining of
Al often with thin walls
Die mould industry which requires
dealing with finishing of hard materials
.
Used to machine such parts as die
casting dies, forging dies, injection
moulds and blow moulds, milling of
electrodes in graphite and copper,
modeling and prototyping of dies and
moulds.
11.
12.
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
Low surface finish High surface finish
Material removal rate is low Material removal rate is
high
Cutting fluid is required Cutting fluid is not required
Comparison
14. 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
15. DISADVANTAGES
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
16. CONCLUSIONS
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 times
conventional cutting speeds
17. 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.
18. References
1. Ashley S., High – “speed machining goes
mainstream”, Mechanical Engineering, May 1995,
(56 – 61).
2. “Die & Mould Making Application Guide”, Sandvik
Coromant, 1999.
3. “Fraisage a grande vitesse, Fabrication des
outillages: des resultats spectaculaires”, L’Usine
Nouvelle, 1995, 16.02, nr 2490, (46 – 48).
4. Grzesik W., “Podstawy skrawania materialów
metalowych”, WNT, Warszawa, 1998.
5. Mason F., “Die and mold finishing. How fast”,
Manuf. Eng. 1995, t. 115, nr 3, s. 35-36,39-40, 42,
45, 47-48.