Documente Academic
Documente Profesional
Documente Cultură
Introduction
Milling is a machining process to remove the material from the work piece by
using the rotary cutter in a direction at an angle with the axis of the tool. After the
Computer Numerical Control (CNC) was introduced, milling machine was involved
into a machining centre that come with automatic tool changers, coolant system, and
enclosures. It also known as vertical machining centres (VMCs) and horizontal
machining centres (HMCs).
High speed milling has assumed as importance and become a versatile
industry application in fulfilling the requirements of high productivity and better quality
due to increased demand and cost reduction in manufacturing. It is typically refers to
making light milling passes at high spindle speed and feed rate to achieve a high
metal removal rate. High geometrical accuracy, low cutting forces are among the
advantages of high speed machining that finds applications mainly in aerospace and
die & mould industry.
Advantages
Cutting the edge of the work piece with a extremely short in time.
Low cutting force gives a small and consistent tool deflection.
Allow for a productive cutting process in small sized components.
Possible to achieve extremely good surface finishing.
Comparison
2.1 Below show the difference between variety types of machinery operation.
Table 1: Comparison of machinery operation.
Type
Drilling
Picture
Meaning
Drilling
is
Description
a Used for last
operation
hole
reaming,
or
or tapping.
cavity.
Grinding is an
Grinding
boring,
operation
The
abrasive
grinding
Very
smooth
surface can be
chips
very
large proper
numbers
grinding
by wheel.
many small
individual
abrasive grains.
Uses of rotating The spindle is
Milling
horizontal
Available in
different size
High
Milling
Speed
Achieving
metal
tables.
high Include automatic
removal tool
changers,
3.0
system,
and enclosures.
Material Use
There are some critical parameters for HSM, as for instance the depth of cut.
Work
PCD, ceramic
slalon, CBN, PCD
Typical
High cutting Typical
High
Material
cutting
speed
cutting
speed
speed
[m/min]
speed
[m/min]
[m/min]
>610
>3658
366
PCD)
1219 (sialon,
Aluminum
[m/min]
>305 (WC, >3050
Cast Iron
PCD)
152
soft
steel
(WC, PCD)
366
cutting
(WC,
ductile
107
free match 107
244
366
244
366
ceramic)
914 (ceramic)
610
steel
alloy
stainless
hardness
244
152
122
213
152
30(WC),
366
274
46(WC),
91(CBN,
183(CBN,
ceramic)
46
84(WC),
ceramic)
91
366(sialon,
213(sialon)
ceramic)
76
107
24
HRC65
Titanium
Super alloy
38
46
61
76
As it was pointed out before HSM is mainly used in die mould industry. Below some
typical cutting data for machining of die are selected in Tables 3 and 4.
Table 3 Typical cutting data for solid carbide end mills with Ti(C,N) or TiAlN coating
in hardened steel: (HRC 54 58).
Type
processing
of vc
[m/min]
Roughing
Semi
100
- 150
finishing
Finishing
200
and 200
Super-finishing 250
ap [%] *
ae [%]*
6-8
35 - 40
fz
[mm/tooth]
0, 05 - 0,
1
0, 05 - 0,
3-4
20 - 40
15
- 0, 1 - 0, 0, 1 - 0, 0, 02 - 0,
2**
2**
Hardness
Conv.
01.2
Steel
150 HB
<300
>400
<900
02.1/2
Steel
330 HB
<200
>250
<600
03.11
Steel
300 HB
<100
39 - 48
>200
<400
03.11
HRC
<80
48 - 58
>150
<350
Steel 04
GCI 08.1
HRC
<40
180 HB
<300
60 - 75 <100
>100
>500
<250
<3000
Aluminum HB
0
>2000
Non - ferr. 100 HB
<300 >1000
* according to Coromant Material Classification (CMC)
4.0
<5000
<2000
Methods
4.1
Such a case takes place when machining press dies or moulds. As it is known
dies consist of cavities in various shapes, with the dimensions and numerous
radii sizes of corners. As an example methods for machining of a cavity below
are described.
Based on experience, or other production information, the surface
machined, can be split up in segments. Each segment can be machined with
one set of insert edges. This technique can be used both for roughing and
finishing. It gives several benefits, namely :
-
higher die or mould geometrical accuracy, which means the finishing tools
can be changed before getting excessive wear.
4.2
In the second method a ball nose end mill is applied. Thus it is common to use a
peck-drilling cycle to reach full axial depth of the cut and then mill the first layer of the
cavity. This is repeated until the cavity is finished as shown in Fig. 2
One of the best methods is linear ramping in X/Y and Z to reach a full axial depth of
the cut. The inclination can start both from in to out or from out to in. It depends on
the geometry of the die or mould. The main problem is how to evacuate of the chips
in the best way. Down milling should be done with a continuous movement and
continuous cutting. It is important to approach with ramping movement or even better
with even circular interpolation, during changing to a new radial depth of cut. (Fig. 3)
The last method is effective when using round insert cutters or end mills with a
ramping capacity. The best choice it is to take the first axial depth of cut using
circular interpolation in helix the rest of machining goes as in the previous point. (Fig.
4)
5.0
Conclusion
Hard competition causes rapid development of the machining technology and
design of new solutions. HSM ensures high metal removal rates, boost productivity,
improve surface finish and eliminates the need of coolant. In spite of high
requirements of machining tools, HSM gives numerous benefits. It allows to shorten
the production.
Significant advantages can be achieved by using high-speed milling in
manufacturing of the products made of advanced materials. Very often high-speed
machining is considered just a way to improve productivity resulted from faster
cutting speeds than used conventionally. Seldom is emphasized that the product
quality can be improved as a consequence of increased accuracy and better surface
finish. Advantages of HSM can be reached only if interactions between the
workpiece and the tool are taken into consideration, the machine tool have been
selected in a right way, NC programs have been made correctly, right cutting
parameters are used and, the last but not least, the safety aspects have been
considered.