This seminar discusses high speed machining (HSM). HSM uses high spindle speeds combined with high feed rates, specialized tools, and tool paths. It allows for high material removal rates, improved surface finish and part accuracy, and reduced cutting forces compared to conventional machining. HSM is commonly used for machining aluminum automotive and aircraft parts, as well as hard metals like dies and molds. While HSM provides advantages like increased productivity, it requires expensive machine tools and advanced programming skills. Overall, HSM is an effective precision machining method when the proper conditions and equipment are used.

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’

7. TOOL HOLDERS AND COLLET
1) ColletS
Triboss Run-out

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.

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.