High-speed cutting machining is a cutting-edge technology that plays a vital role in the 21st century. It is known for its efficiency, precision, and excellent surface quality. As industries like automotive, aerospace, mold manufacturing, and instrumentation continue to evolve, high-speed cutting has become increasingly popular due to its significant technical and economic benefits. It is now an essential component of modern advanced manufacturing systems.
One of the key features of high-speed cutting is its ability to drastically increase productivity without requiring additional equipment. This is achieved through process intensification and the use of versatile machine tools. The main characteristics include:
1. **High cutting speed**: Typically 5 to 10 times faster than traditional methods.
2. **High spindle speed**: Usually between 10,000 to 20,000 revolutions per minute (RPM).
3. **High feed rate**: Often ranging from 15 to 50 meters per minute, with some reaching up to 90 m/min.
4. **Material-specific considerations**: The definition of high-speed cutting varies depending on the workpiece and tool materials.
5. **Optimized frequency alignment**: The cutting edge passing frequency is closely aligned with the natural frequency of the machine-tool-workpiece system, enhancing stability and performance.
In 1992, Professor H. Schulz from Darmstadt Institute of Technology introduced the concept of High Speed Manufacturing (HSM). He defined the transition zone as the range where high-speed cutting becomes effective for different applications, marking a significant milestone in the field.
Compared to conventional machining, high-speed cutting significantly increases the cutting speed, leading to higher friction between the tool and the workpiece. This results in elevated temperatures at the chip-tool interface, which can soften or even melt the material, reducing cutting forces and improving chip evacuation. As a result, more than 70% of the heat is carried away by the chips, minimizing thermal deformation and improving machining accuracy. The advantages of high-speed cutting include increased productivity, improved surface finish, and reduced tool wear.
In the automotive industry, high-speed machining is particularly useful for complex parts such as engine blocks, cylinder heads, and car body molds. These components often require fast production cycles and frequent design changes, making high-speed cutting an ideal solution. Flexible production lines, such as the FTL (Flexible Transfer Line) and FMS (Flexible Manufacturing System), are widely used to maximize efficiency and adaptability.
For example, the FTL system utilizes high-speed machining centers that offer miniaturization, flexibility, and quick changeovers. In one case, an SAIC engine company uses this system to process engine blocks and cylinder heads efficiently. Additionally, multi-functional tools are employed to reduce the number of tool changes and improve overall productivity.
Another example is the use of high-speed milling in mold manufacturing. For instance, safety door lock injection molds made from hard die steel (HRC54) can be machined using small-diameter tools (as small as φ0.6mm) with high cutting speeds and minimal depth of cut. This results in a surface roughness of Ra 0.4μm, eliminating the need for manual finishing and significantly reducing processing time.
High-speed cutting also plays a crucial role in the production of automotive covers and instrument panels. These parts often have complex geometries and thin walls, making them challenging to machine with traditional methods. High-speed milling allows for precise and efficient machining, ensuring both surface quality and dimensional accuracy.
To support these operations, high-speed cutting machine tools must meet strict requirements. They need high spindle speeds, excellent dynamic performance, and strong rigidity to handle the intense demands of high-speed operations. Innovations such as water-cooled servo motors, high-pitch ball screws, and laser tool setting devices are essential for maintaining accuracy and stability.
In China, companies like Zhejiang Wanxiang and Changchun FAW Fuao have adopted advanced high-speed machining centers from manufacturers like Mikron. These machines use artificial marble beds and closed O-shaped structures to enhance vibration absorption and stiffness. With spindle speeds up to 12,000 RPM and feed rates exceeding 80 m/min, they are well-suited for high-precision automotive applications.
The demand for high-speed machining equipment and advanced tooling continues to grow, driven by the rapid development of the automotive industry in regions like Shanghai and East China. Companies such as SAIC Volkswagen and General Motors are investing heavily in high-speed cutting technologies to stay competitive and meet the evolving needs of the market.
Simple Communications Controller,Festo Valve Island,Pneumatic Valve Island,Smc Valve Island
ShinYee (Zhejiang) Pneumatic Technology Co., LTD , https://www.pneuvalve.com