Project Case
Misconceptions and Concepts in High-Speed Milling, Did You Know?
In the manufacturing industry, several common misconceptions surround high-speed milling:
1. High-speed milling is just a milling machine equipped with a high-speed spindle.
2. The higher the spindle speed, the faster the processing speed.
3. High-speed milling is a new technology designed to replace traditional milling machines.
4. A spindle speed of 20,000 rpm is sufficient for mold production.
5. High-speed milling only involves increasing the size and speed of the axial server.
6. High-speed milling can only process electrodes.
...
In reality, high-speed milling is a new technology with its own philosophy and applications:
To fully harness the efficiency of high-speed cutting, a close collaboration in every aspect is essential. If any element in the process is poorly matched, the benefits of high-speed cutting cannot be realized.
Components of high-speed milling include:
- High-speed tool holders and tools
- High-speed spindle
- High-power X, Y, Z axes
- High-speed CNC controller
- High-speed programming strategies
Conditions during high-speed cutting:
As the speed increases to a certain point, the temperature and cutting forces of the tool gradually decrease. This phenomenon is utilized in high-speed milling technology.
Comparison between traditional milling and high-speed milling:
Traditional Milling:
- Large material removal area but slow speed
- High temperature generation
- Low finished accuracy, rapid tool wear
- Poor surface quality
High-speed Milling:
- Small material removal area but fast speed
- Low temperature generation
- High finished accuracy, slow tool wear
- Excellent surface quality
Applications of high-speed milling:
1. To match spindle specifications, tool diameters should not exceed 16mm (HSK-E40) for stability and safety during processing.
2. Compared to traditional milling, high-speed milling has a relatively low cutting removal rate, making it suitable for small parts and mold processing.
3. Applicable to new processing applications such as thin-sheet machining and micro-machining.
4. Introduces a new processing method for soft or superhard materials. For example, a part with a wall thickness of 0.5mm in aluminum may be impossible to produce without high-speed milling technology.
1. High-speed Tool Holders and Tools:
In reality, it's not the machine that performs the cutting, but the tools. Tools, like tires on a car, are the only parts in contact with the workpiece. Choosing tools depends on factors such as diameter, type, shape, material, coating, and quality, and adjustments may be needed based on actual processing conditions.
2. High-speed Spindle:
In reality, a high-speed spindle is like the high RPM engine in an F1 car. Spindles can be roughly categorized into two types: those with bearings for high torque (currently reaching speeds up to 54,000 rpm) and those without bearings (gas-driven) for high speed (>100,000 rpm). High torque allows cutting larger materials with larger tools and harder materials, while high speed allows faster cutting rates and achieves High-Speed Machining (HSM) effects.
3. High Dynamic Performance of Each Axis:
In reality, the machine's bed structure is like a car's chassis, robust and capable of absorbing shocks and vibrations. Traditional hard rails can achieve better accuracy through adjustments on the machine, but they cannot match the high-speed capabilities of linear guideways. High-speed axes and a sturdy bed structure are crucial for acceleration, reducing time wastage, achieving better cutting surfaces, and minimizing tool wear.
4. High-speed Milling Controller CNC:
In reality, the controller is like the driver, and its operating skills determine the success of the milling process. It requires foresight, sensitivity, and quick reaction capabilities.
5. CAM Processing Strategies for High-speed Milling:
In reality, there are many paths to reach one point from another, but all paths will produce different effects in terms of speed, surface quality, and more.
With a vision of boosting thermal management through innovation, Metalli is dedicating to creating a better thermal management solution for your application.
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