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HIGH SPEED CNC HIGH SPEED CNC

Presented By Satish Baburao Ligade

I st year M.Tech(CAD-CAM)

ContentsContents IntroductionIntroduction High Speed CNCHigh Speed CNC Typical High speed CNCTypical High speed CNC AdvantagesAdvantages Application areasApplication areas Demands of the machineDemands of the machine Cutting toolCutting tool ComparisonComparison DisadvantagesDisadvantages ConclusionsConclusions

IntroductionIntroduction

Carl Salomon assumes that Carl Salomon assumes that

“ “At a certain cutting speed which is 5-10 At a certain cutting speed which is 5-10 times higher than in conventional times higher than in conventional machining the chip removal temperature machining the chip removal temperature at the cutting edge will start to at the cutting edge will start to decrease”decrease”

HSM is a powerful machining method HSM is a powerful machining method that combines high feed rates with high that combines high feed rates with high spindle speeds, specific tools and spindle speeds, specific tools and specific tool motionspecific tool motion

HSM

Fig.1

High Speed CNCHigh Speed CNC

Combine roughing and finishing passesCombine roughing and finishing passes Machining at resonant frequency of machineMachining at resonant frequency of machine Improved life of spindle, secure clamping of Improved life of spindle, secure clamping of

tools & life of toolstools & life of tools Saving of 40% time in whole processSaving of 40% time in whole process It prefers smaller tools that moves fasterIt prefers smaller tools that moves faster

High Speed CNCHigh Speed CNC

Typical Datron High Speed CNC Typical Datron High Speed CNC Intelligent ProbingIntelligent ProbingSpindle speed upto 60,000rpmSpindle speed upto 60,000rpmAutomatic tool managementAutomatic tool managementSpray-mist coolant systemSpray-mist coolant systemIntegrated work holdingIntegrated work holdingLow power technologyLow power technology

ProbingProbing

Probe recognizes irregular work-Probe recognizes irregular work-piece topography and compensates piece topography and compensates for it dynamically.for it dynamically.

job setup times reduced and job setup times reduced and workpiece rejection is minimized.workpiece rejection is minimized.

Compensate for material variationCompensate for material variation Allow for reverse engineering of Allow for reverse engineering of

many partsmany parts

Fig.2 Z correction probe

Spindle speedSpindle speed

Spindle speed ranges from 3000-Spindle speed ranges from 3000-60000rpm.60000rpm.

Conventional CNC uses large motors Conventional CNC uses large motors & tools& tools

Motor and spindle act as one bodyMotor and spindle act as one body Low machining force, less vibrations, Low machining force, less vibrations,

high feed rates high feed rates High speed is achieved by AC High speed is achieved by AC

induction motorsinduction motors Axes are actuated by permanent Axes are actuated by permanent

magnet linear synchronous motorsmagnet linear synchronous motors

Fig.3

Spray coolantSpray coolant

Ethanol is used as ideal coolantEthanol is used as ideal coolant Spray technology & low viscosity Spray technology & low viscosity

allows ethanol to cover more area & allows ethanol to cover more area & cools faster cools faster

Low evaporation point makes Low evaporation point makes disposal easydisposal easy

Used for non-ferrous materialUsed for non-ferrous material

Fig.4

Low-Power Technology

Designed with smaller motorsDesigned with smaller motors Most of CNC runs on 440volt,20A Most of CNC runs on 440volt,20A

&3 phase supply &3 phase supply High speed CNC runs on 200 High speed CNC runs on 200

volt,10A & 1phase supplyvolt,10A & 1phase supply Decrease energy consuptionDecrease energy consuption Fig.5

Automatic Tool ManagementAutomatic Tool Management

Conventional CNC detect tool Conventional CNC detect tool breakage but not compensatebreakage but not compensate

Not working with micro tools Not working with micro tools High speed CNC consist of tool High speed CNC consist of tool

checker and tool changerchecker and tool changer Tool checker measures tool length & Tool checker measures tool length &

detect tool breakage detect tool breakage Tool changer replace the toolTool changer replace the tool

Fig.6

Advantages Advantages High material removal rateHigh material removal rate High surface finish High surface finish Increased productivityIncreased productivity Machining of any material using ultra-high performance toolsMachining of any material using ultra-high performance tools Reduction in lead timesReduction in lead times Low cutting force ,reduce cycle times & improve accuracy.Low cutting force ,reduce cycle times & improve accuracy. Cutting tool and work piece temperature are kept lowCutting tool and work piece temperature are kept low It eliminates the need of coolantIt eliminates the need of coolant High Speed CNC is experienced in various types of materials High Speed CNC is experienced in various types of materials

such as aluminum, stainless steels and titanium as well as such as aluminum, stainless steels and titanium as well as inconels, hastelloys, copper, brass, plastic and moreinconels, hastelloys, copper, brass, plastic and more

FEATURESFEATURES EFFECTSEFFECTS

Reduced heat Reduced heat transfer in to the transfer in to the work piecework piece

Part accuracyPart accuracy

Reduction of Reduction of cutting forcescutting forces

Part accuracyPart accuracy

Surface qualitySurface quality

Increased cutting Increased cutting speedspeed

Stability of rotating Stability of rotating cutting tool feed rate cutting tool feed rate

Increased material Increased material removalremoval

ApplicationsApplications Mostly used in milling hard mold and die steels Mostly used in milling hard mold and die steels Industry which deals with the machining of Al to Industry which deals with the machining of Al to

produce automotive components, small computer produce automotive components, small computer parts or medical devicesparts or medical devices

Aircraft industry involves machining of Al often with Aircraft industry involves machining of Al often with thin wallsthin walls

Prototyping of dies and moldsPrototyping of dies and molds Semiconductor parts, microwave housingSemiconductor parts, microwave housing

Demands of the machineDemands of the machine

Spindle speed range <=60000 rpmSpindle speed range <=60000 rpm Cutting speed range=1500-5000m/minCutting speed range=1500-5000m/min Spindle power >22 KWSpindle power >22 KW Programmable feed rate 2-50m/minProgrammable feed rate 2-50m/min Rapid travels <90 m/minRapid travels <90 m/min Block processing speed 1-20 msBlock processing speed 1-20 ms High thermal stability and rigidity in spindleHigh thermal stability and rigidity in spindle Air blast/coolant through spindleAir blast/coolant through spindle

High Speed CNC Mill - YouTube.webm

Cutting toolsCutting tools

1.1. TiN and TiCN coated Carbide for materials with TiN and TiCN coated Carbide for materials with hardness less than 42 HRChardness less than 42 HRC

2.2. TiALN coated Carbide for materials with hardness TiALN coated Carbide for materials with hardness 42 HRC and above42 HRC and above

3.3. For special applications like hard turning For special applications like hard turning (HRC 60-65) PCBN is used(HRC 60-65) PCBN is used

4.4. Cubic boron nitrite (CBN) and ceramic for cast ironCubic boron nitrite (CBN) and ceramic for cast iron

5.5. Poly crystalline diamonds (PCD) and Cermets are Poly crystalline diamonds (PCD) and Cermets are used for aluminumused for aluminum

ComparisonsComparisonsMODEL(HAAS) VF-2

Travel / Table X axis travel mm 763

Yaxis travel mm 406

Z axis travel mm 508

Spindle nose to table surface mm 102-610

Table size mm/mm 914x 356

Max. table loading kgs 1361

T slot (N x W x P) 3x 16 x 125

Spindle / Feed Speed (Std.) rpm 8000

Speed (Opt.) rpm 8100

Spindle taper BT40

Feed X、Y、 Z(G00) 25.4/25.4/25.4 m/min

Cuting feed 16500 mm/min

Tool Magazine Taper BBT40

Tool length mm 300

Tool magazine capacity 20

Max. tool diameter 80

Max. tool weight kgs 7

Tool change time SEC 4.5

Machine Dimension Length mm 4395

Deepth mm 2250

Height mm 2900

Machine Weight N.W. kgs 3300

G.W. kgs 3500

MODEL(SAN EAGLE) SHD-600

Travel / Table X axis travel mm 600

Yaxis travel mm 550

Z axis travel mm 360

Spindle nose to table surface mm 360

Table size mm/mm 600 x 550

Max. table loading kgs 300

T slot (N x W x P) 4 x 14 x 100

Spindle / Feed Speed (Std.) rpm 30,000

Speed (Opt.) rpm 36,000

Spindle taper HSK-E40

Feed X、Y、 Z(G00) 30/30/24 m/min

Cuting feed 20000 mm/min

Tool Magazine Taper HSK-E40

Tool length mm 150

Tool magazine capacity 20

Max. tool diameter 40

Max. tool weight kgs 3

Tool change time SEC 7

Machine Length mm 2080

Deepth mm 2180

Height mm 2550

Machine Weight N.W. kgs 4500

G.W. kgs 5000

ComparisonsComparisons

Conventional CNCConventional CNC High speed CNCHigh speed CNC

Max speed 600 m/minMax speed 600 m/min Speed starts at 600 m/minSpeed starts at 600 m/min

Max feed ~40 ipmMax feed ~40 ipm Feed starts at 100 ipmFeed starts at 100 ipm

Require high levels coolantRequire high levels coolant With coolant ,feed rate can With coolant ,feed rate can go more than 2000 ipmgo more than 2000 ipm

No need for coolant for No need for coolant for low feed ratelow feed rate

Between conventional and high speed machines

Conventional CNCConventional CNC HS CNCHS CNC

The contact time between The contact time between tool and work is largetool and work is large

Contact time is shortContact time is short

Less accurate work pieceLess accurate work piece More accurate work pieceMore accurate work piece

Cutting force is largeCutting force is large Cutting force is lowCutting force is low

Low surface finishLow surface finish High surface finishHigh surface finish

Material removal rate is lowMaterial removal rate is low Material removal rate is Material removal rate is highhigh

Cutting fluid is required Cutting fluid is required Cutting fluid is not requiredCutting fluid is not required

Comparison between convl and HSM process

DisadvantagesDisadvantages Faster wear of guide ways, ball screws and spindle Faster wear of guide ways, ball screws and spindle

bearings, leading to higher maintenance costs. bearings, leading to higher maintenance costs. Need for expensive and special machine tools with Need for expensive and special machine tools with

advanced spindle and controllersadvanced spindle and controllers Excessive tool wearExcessive tool wear Good work and process planning necessaryGood work and process planning necessary Consequently, finding suitably trained staff can be Consequently, finding suitably trained staff can be

difficultdifficult Only tools with posted maximum spindle speed can Only tools with posted maximum spindle speed can

be used. be used.

ConclusionsConclusions HSM is not simply high cutting speed .It should be HSM is not simply high cutting speed .It should be

regarded as a process where the operations are regarded as a process where the operations are performed with very specific methods and precision performed with very specific methods and precision equipmentequipment

Many HSM applications are performed with Many HSM applications are performed with moderate spindle speeds and large sized cuttersmoderate spindle speeds and large sized cutters

High speed CNC is high productive machining in High speed CNC is high productive machining in small sized components in roughing to finishing and small sized components in roughing to finishing and in finishing to super finishing in components of all in finishing to super finishing in components of all sizes.sizes.

Need for further improvement of quality and Need for further improvement of quality and optimization of cost.optimization of cost.

Questions

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