High-speed machining by Bert P. Erdel

By Bert P. Erdel

High-Speed Machining describes the parameters and production features for brand spanking new complicated machining techniques and demanding situations the conventional methods of completing complicated workpieces. the writer systematically describes the numerous aspects of what high-performance machining rather capability and the way it may be pursued comfortably and unprecedented luck. The publication illustrates confirmed productiveness advancements and price saving via sensible purposes. It additionally represents the present and destiny kingdom of complex machining procedures, approach, and strategies

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1 µm). Some manufacturers’ rule-of-thumb is to filter all fines larger than 10% of the tightest tolerance of the part machined. Proper fine filtering must be part of the overall coolant management strategy. Machining without coolants, involving operations that are normally done with cutting fluids, has consequences for the machine specifications. However, the switch over from wet to dry involves relatively few technical changes, compared to the otherwise complex machine-tool design. The most influential factors for machining are thermal stress and chip control.

Figure 4-4. Machining centers’ axes acceleration. pmd High-speed Machining 32 4/10/03, 9:43 AM Machine-tool Technology What holds true for often unnecessary, extreme high spindle speeds beyond 18,000–20,000 rpm within regular part production envelopes is also true for excessively high acceleration rates, as shown in Figure 4-5. Productivity and precision must be paired with economics in regular manufacturing environments. However, there is more to be said about acceleration. Due to its exponential relationship, it takes four times the amount of power to double acceleration.

A smaller amount of the heat generated at the cutting point is transferred into the workpiece and cutting material than is normal with traditional machining, because much of the heat is removed with the chips. The lower tangential loads on the cutting tool simplify part-fixture design and allow for easy machining of thin-walled workpieces. pmd 21 21 4/10/03, 9:42 AM Characteristics of High-speed Machining Figure 3-1. Machining characteristics. rule, a welcome bonus, as are the higher chip-load demands provided there are well-defined tool-chip galleys and a reliable transport of the chips out of the machining area.

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