In the manufacturing industry, there are many misconceptions regarding high-speed milling, including the following:
High-speed milling is just a milling machine equipped with a high-speed spindle
The higher the spindle speed, the faster the processing speed
High speed milling machine is a new technology, just to replace the general traditional milling machine
A 20,000 rpm spindle is sufficient for mold production needs.
High-speed milling is only accelerated by increasing the axial server
High-speed milling can only process electrodes
………
In fact, high-speed milling is a new technology and new application philosophy:
If you want to bring out the efficiency of high-speed cutting, you must work closely with each link. If one of the links is not well matched, you will not be able to bring out the efficiency of high-speed cutting.
High-speed tool holders and cutters
high speed spindle
Highly powerful X, Y and Z axes
High Speed CNC Controller
high speed programming strategy
The situation when cutting at high speed
As the rotation speed increases to a certain level, the temperature and cutting force of the tool gradually decrease. This phenomenon is used in high-speed milling technology.
Conventional milling
High speed milling
Dispersion rate of high speed cutting heat source
Machining concepts of high-speed milling (HSM) and high-performance milling (HPM)
Example: Rough machining of hardened steel, material hardness >55HRC
Application area of high speed milling
1) In order to match the specifications of the spindle and ensure the stability and safety of processing, the tool diameter does not exceed 16mm (HSK-E40).
2) Compared with traditional milling, the cutting removal rate of high-speed milling is relatively low, which is very suitable for small parts and mold processing applications.
3) It can be used in new processing applications such as thin sheet processing and micro-processing.
4) It is a new concept processing method for soft materials or ultra-hard materials.
Example: An aluminum part with a wall thickness of 0.5 mm cannot be produced without high-speed milling technology.
1. High speed matching tool holder and tool
In fact, it is not the machine that cuts, but the tool! Tools are like the tires on a car, the only parts of the car that touch the ground. Good and suitable tires are the key to success in racing. The selection of cutting tools and processing conditions can be based on information provided by the cutting tool manufacturer, but the user should always make adjustments based on actual processing conditions.
Tool selection criteria:
Diameter (depending on the geometric dimensions and precision of the part)
Type (roughing, finishing, grooving, 3D contouring, edge machining…)
Shape (ball cutter, round nose cutter, multi-edge cutter, etc.)
Materials (high speed steel, cemented carbide, cermet, diamond, cubic boron nitride CBN)
Tool coating (TiN, TiCN, TiAlN…)
Quality (radial voice, shape precision, dynamic balance, rigidity)
2. High speed spindle
In fact, the high-speed spindle is comparable to the high speed and power of an F1 racing car’s engine.
Pins can be roughly divided into two specifications:
1) With ≥ high torque bearings, the current maximum speed can reach 54,000 rpm.
2) Without bearing (gas) ≥ low torque, but very fast speed (>100 rpm).
High torque allows you to cut larger materials, using larger tools and harder materials. The high rotation speed allows for faster cutting rates and achieves HSM effects.
3. High dynamic performance of each axis
In fact, the machine bed structure itself is like the chassis of a car, strong and safe to absorb shock and vibration.
Traditional hard rails can achieve better precision through adjustments on the machine table, but they cannot achieve the high-speed processing that linear sliding rails can achieve. With high-speed axles and a solid bed structure, acceleration is a key factor. High acceleration spindles reduce wasted time, provide better cutting surfaces and reduce tool wear.
4. High speed CNC milling controller
In fact, the controller is like a driver, and his operational skills determine the outcome of the car. This requires forethought, sensitivity and rapid response skills.
5. CAM processing strategy for high-speed milling
In fact, there are many paths to get from one point to another, but all paths will have different effects on speed, area, etc.
Daguang focuses on providing solutions such as precision CNC machining services (3-axis, 4-axis, 5-axis machining), CNC milling, 3D printing and rapid prototyping services.
