1. High Speed Machining Time is money

2. What is it?Usually associated withany spindle speed above15kMore than just a fastspindleThe whole machinemust be considered 3. Important FactorsCasting and baserigidityThermal growth controlAxis position feedbackTool retention 4. Breaking Tradition Finish machining hardened materials has historically been EDM HSM traditionally focused on the die mold industry More prevalent today 5. Who uses HSM?The application of HSM often requires a substantial upfrontinvestment: suitable machine tool, specially designed tooling, andan advanced CAM system.Aluminum & CompositesDieGeneral Production Aerospace Casting Dies Excessive Roughing Automotive Components Forging Dies Mid to High Production Small Computer PartsInjection MoldsExcessive Rouging Ops Medical Devices Electrodes Thin Walled Parts Modeling & Prototyping Finishing Hard Materials 6. Advanced CAM Toolpaths Produces a consistent chip load and tool engagement especially in corners Allowing for dramatically increased parameters Small diameter tooling can also be pushed far beyond traditional limits 7. Traditional Process vs. HSM Traditional Processing Racetrack toolpath patterns resulting in sharp corners Cutting parameters limited due to the increased linearMaterial1018 CRS forces against the toolTooling 3/8 (9.5mm) Solid Carbide 3 Flute EndmillSpindle Speed 4,500 RPMDepth of Cut.25 (6.35mm)Intermittent over-Feedrate30 ipm (762 mmpm) engagement caused extremeChip Load .002 (.050mm) tool wearCycle Run Time 11 Minutes, 16 Seconds 8. Traditional Process vs. HSM HSM ProcessingMuch different toolpathpattern NO sharp cornersDOC, Feedrates, and RPMdramatically increasedMaterial 1018 CRSTooling3/8 (9.5mm) Solid Carbide 3 Flute Endmill No noticeable wear on theSpindle Speed12,000 RPMtool tool will last thruDepth of Cut .625 (15.875mm) FULL DEPTHFeedrate 157 285 ipm (3987 7238 mmpm)several partsChip Thickness .0033 (.0838mm)Cycle Run Time 2 Minutes, 51 Seconds 9. Standard Spindle - 12,000 RPMSame HSM processingMaterial 1018 CRS strategy, depth of cut, chipTooling3/8 (9.5mm) Solid Carbide 3 Flute Endmillthickness, and toolingSpindle Speed12,000 RPMDepth of Cut .625 (15.875mm) FULL DEPTHFeedrate 157 285 ipm (3987 7238 mmpm)33% faster spindle Chip Thickness .0033 (.0838mm)Cycle Run Time 2 Minutes, 51 Secondsfeedrates can be increased18k = 33% FasterSpindle Speed18,000 RPMDepending on geometry,Cycle Run Time 1 Minute, 54 Seconds UltiMotion could be evenfaster 10. Show me the moneyTraditional ProcessingHigh Speed Machining High Speed Machining(12K) (12K)(18K)Hourly Shop Rate$60.00 $60.00 $60.00Hourly Burden Rate$35.00 $35.00 $35.00Cycle Time11 min : 16 sec 2 min : 51 sec 1 min : 54 secCost to Produce$6.57$1.67$1.11Quoted Price$13.50 $13.50 $13.50Profit per Part$6.93$11.83 $12.39Profit x 100 pieces$693.00$1,183.00$1,239.00Profit x 500 pieces$3,465.00$5,915.00$6,195.00 11. UltiMotion Dynamic Variable Look Ahead up to 10,000 blocks UltiMotion is predictive controls velocity and acceleration based on upcoming obstacles Guarantees look ahead is always adequate enough for upcoming maneuvers 12. UltiMotion Exact same HSM program 29% cycle time reduction Improved surface finish qualityUltiMotion StandardMotion