Success with high-speed machining requires a thorough under-standing of the required tools and methods and of their benefits and limitations.

Speeds, Feeds and Tools of High-Speed Machining
High-speed machining features spindle speeds of 10K to 40K rpm, feedrates of up to 150 to 400 inches per minute, with relatively small depths-of-cut. It is most often used for applications that demand significant material removal or that require extremely hard metals. Applications range from automotive molds, dies, press tools and other large steel components to hard-metal machining, custom prototype parts, specialized medical products, such as hip and knee joints, and R&D projects with unusual materials.

Because of the extreme speeds involved in high-speed machining, the technique places unique demands on every piece of hardware that’s used in the process. Milling machines, cutters, holders and other components must be designed to maximize stability and minimize vibration, since excessive vibration can damage surface finish, reduce the life of the cutter and other tools, and even ruin tools or jobs.

CNC machines are built for maximum rigidity and cast rate. Cutters are made from solid, sub-micro grain carbide for maximum strength and to tolerate heat expansion of the holders. Cutter holders employ shrink-fit technology to maximize balance and minimize air friction. For the control systems that translate the software commands into actions, digital drives and direct measuring systems are required to produce the highest possible precision, and most accurate repeatability.