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High Speed Machining
           Time is money…
What is it?

              Usually associated with
              any spindle speed above
              15k

              More than just a fast
              spindle

              The whole machine
              must be considered
Important Factors
                    Casting and base
                    rigidity

                    Thermal growth control

                    Axis position feedback

                    Tool retention
Breaking Tradition


                     Finish machining hardened
                     materials has historically
                     been EDM

                     HSM traditionally focused on
                     the die mold industry

                     More prevalent today
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
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
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
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
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
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
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
UltiMotion


                               Exact same
                               HSM program

                               29% cycle
                               time reduction

                               Improved
                               surface finish
                               quality


UltiMotion   Standard Motion
High speed machining imts 2012

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High speed machining 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. 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