HARDNESS: WHEN PERFORMING HIGH-SPEED MACHINING FOR CAVITY AND CORE PIECES, WHAT IS THE ALLOWABLE

HARDNESS OF THE WORKPIECE?

Depending on the machine's rigidity and the spindle technology being used, Field quotes hardness of up to 70 HRc being
machined with the proper machining techniques. The most common hardness being used in high-speed applications seems
to be around 50 HRc. In fact, most of the high-speed machining techniques were developed for this hardness.
A common industry misconception is that machining hardened metal is difficult to do at high speeds. High-speed
machining, with the proper programming actually facilitates the machining of hardened metals. "In some test cut
applications, I've cut H13 50 HRc just as easily, and as accurately as softer metals," says Field. "The harder the metal the
more brittle it becomes and it can be more easily chipped off than softer, gummier metals. And since material is chipped
off more quickly in high-speed applications, more heat is released into the chip."
CUTTERS: WHAT KIND OF CUTTERS ARE NECESSARY TO MACHINE HARDENED METALS AND NON-HEAT TREATED
METALS?
For tools ranging from 1.5" to .5" diameter, carbide insert tools are usually the tool of choice. Several tooling
manufacturers offer a variety of coatings and geometries. TiCN coatings are sufficient for material less than 42 HRc,
while ALTiN coatings are used for material 42 HRc and over. For tools with a diameter .5" and under, tooling with an 8 to
12 percent cobalt content submicrograin is best suited. And while cutters for high-speed machining will normally not
exceed 1.5" in diameter, face milling in high-speed applications uses tooling with diameters up to 3".
"When purchasing solid carbide tools," says Field, "the higher quality tools will definitely pay for themselves with longer
tool life and better application results." Field also recommends testing tooling within each specific application to
determine the best speeds and feeds for each tool. "Use your tooling to your machine's specifications, not the tooling
supplier's specifications." says Field. "Tooling manufacturers cannot test their products on every machining center on the
market--it is just not feasible. Machine tool manufacturers purchase a wide variety of tooling and know to what levels
they can be taken. Your machine tool manufacturer can help you in this regard while working on the application.
Regardless, never exceed the maximum rpm rating for insert cutters or toolholders."
TOOLHOLDERS: WHAT KIND OF TOOLHOLDERS SUIT HIGH-SPEED MACHINING BEST, AND DO BALANCED
TOOLHOLDERS REALLY MAKE A DIFFERENCE?
When machining at high rpm, toolholder balance is critical. Balanced toolholders and the runout of the tool/toolholder
combination must be examined carefully for high-speed machining. "The balance of the toolholder should be less than the
G2.5 specification and, depending on the rpm being used, this might need to be checked by asking the manufacturer,"
says Field. "It is possible to buy a 15,000 rpm toolholder that is not balanced or within the G2.5 specification. The rpm
ratings do not necessarily provide enough information about the spindle--ask your tooling supplier. Surface finish and
spindle damage can occur if it's not within the above specifications. Runout should be no more than .0002". Less runout
translates into longer tool life. Probably the best holder for high-speed machining is shrink-fit, as it has more than
acceptable gripping force and perfect runout characteristics. Plus, by having no moving parts, it is very easy to balance.
The second-best toolholders, in my opinion, are probably hydraulic chucks."
COOLANT: IS HIGH-PRESSURE, THROUGH-SPINDLE COOLANT NECESSARY FOR HIGH-SPEED MACHINING?
While this has been the predominant approach, other methods of heat dissipation have evolved. Makino's patented Flush
Fine machining process can now be implemented using nozzle air, or through-spindle air. The Flush Fine process is a high-
speed, high-definition and low-heat machining process that combines high spindle speeds with precisely controlled, high-
pressure coolant or forced air to blast away chips and prevent heat buildup, either in the workpiece or the tool. This
permits high speed machining with greater thermal stability and chip control, resulting in a superior accuracy and finish,
as well as high metal removal rate and longer tool life. This also results in minimal workpiece movement during and after
machining, which is traditionally caused by machining stresses and heat.
CAD/CAM: HOW DOES HIGH-SPEED MACHINING IMPACT CAD/CAM?
This CAM system must have toolpaths set within specific tolerances for optimum results, including the step over and pick
feed. The CAM tolerance is the amount of deviation that is allowable from the actual surface of the model. The tolerance
for finishing should be set at no more than .0001" for the optimum finish. The step over or pick feed is the value used to
establish the cusp height. The cusp should be set to .00005" or less for optimum finish. Editor's note: more information on
the relationship between CAD/CAM and high-speed machining can be found in Competitive Mold Maker's 3.2's CAD/CAM
FAQ, or you can visit www.moldmakermag.com and read it online.
LOOK AHEAD: HOW MUCH BLOCK LOOK AHEAD IS NECESSARY TO CONDUCT HIGH-SPEED MACHINING?
Field notes that a common misconception about look ahead is that a thousand block look ahead is necessary to conduct
high-speed machining. "This is an incorrect assumption," says Field. "If the machining center is designed well, it will not
need to rely on this large of a look ahead capability. The machining center relies more on the data transfer time, which
ensures there is no data starvation."
Look ahead tracks surface geometry, allowing the machining center to accelerate and decelerate most efficiently through
tooling compensation. "Makino's Super Geometric Intelligence (GI) software greatly simplifies programming," says Field.
"Especially for corners, curves and other part geometry changes, Super GI helps prevent overshoot. Basically, you
program for chip load, then enter the highest speeds and feeds that will give you the desired chip load. In machining
operations, Super GI takes over and adjusts feeds on the fly to maintain that chip load, enabling the machining center to
hold high speeds longer before a toolpath change, minimize slowing while maintaining programmed toolpath/axis changes
and resume high speeds faster."
MACHINING CENTER DESIGN: CAN ANY MACHINING CENTER PERFORM HIGH-SPEED MACHINING?
The machining center is the most important factor in successful high-speed machining. "Older CNC machines simply
cannot support the speeds and feeds we are describing," says Field. "A machining center must have been designed with
high-speed applications in mind to provide quality results. For example, the machining center requires high levels of
rigidity. The spindle must also be rigid with very low vibration characteristics. The machining center's servos and control
must be advanced enough to support look ahead and quick response times and a high data transfer rate is necessary to
handle larger sized programs. I've seen shops attempt to use conventional CNCs for high-speed applications and the
results are not what they expect. These machines cannot support the physics of high-speed machining."
Source: Competitive Mold Maker, Volume 4, Number 1
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