1. High Speed Machining
Time is money…

2. What is it? Usually associated with any spindle speed above 15k
More than just a fast spindle
The whole machine must be considered
Usually associated with any spindle speed above 15k – but HSM is more than just a faster spindle and increased feedrates
The whole machine must be considered – tool holder type, the machine base, linear guides, overall thermal stability, contouring speeds, CPU processing speed, control look- ahead, position feedback method, etc…

3. Important Factors Casting and base rigidity Thermal growth control
Axis position feedback
Tool retention
Usually associated with any spindle speed above 15k – but HSM is more than just a faster spindle and increased feedrates
The whole machine must be considered – tool holder type, the machine base, linear guides, overall thermal stability, contouring speeds, CPU processing speed, control look- ahead, position feedback method, etc…

4. Breaking Tradition
Finish machining hardened materials has historically been EDM
HSM traditionally focused on the die mold industry
More prevalent today
The traditional method of finish machining hardened materials has been EDM In applications where HSM can replace the EDM process there will be considerable cost and cycle time reductions
During the past 10 to 15 years HSM has been primarily focused on the mold and die industry that uses pre-hardened materials and hardened tool steels - ranging in hardness from HRC
In recent years HSM has become much more prevalent - today many job-shops are also benefiting from HSM techniques

5. Who uses HSM?
The application of HSM often requires a substantial upfront investment: – suitable machine tool, specially designed tooling, and an advanced CAM system.
Aluminum & Composites
Die
General Production
Aerospace
Automotive Components
Small Computer Parts
Medical Devices
Thin Walled Parts
Casting Dies
Forging Dies
Injection Molds
Electrodes
Modeling & Prototyping
Finishing Hard Materials
Excessive Roughing
Mid to High Production
Excessive Rouging Ops
The application of HSM techniques often requires a substantial investment – suitable machine tool, specially designed tooling, and an advanced CAM system capable of producing the enhanced toolpaths.
Aluminum & Composite parts – aerospace, automotive components, small computer parts, and medical devices – usually involves the removal of large amounts of material and often parts with very thin walls. In addition to high metal removal rates, HSM techniques can prevent chatter and poor surface finishes when machining thin walled features.
Die & Mold – casting dies, forging dies, injection molds, electrodes, modeling or prototyping – usually associated with finish machining of hard materials. HSM techniques are very effective when machining with small diameter tooling often associated with the die-mold industry.
General Production – HSM techniques can drastically impact cycle times - especially when excessive roughing operations are necessary.

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
Produces a consistent chip load and tool engagement – especially in corners and when changing directions – thus preventing the tool from experiencing unstable or varied cutting pressures
Allowing for dramatic increased cutting depths, higher RPM’s, and increased cutting speeds – all with out sacrificing surface finish
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 linear forces against the tool
Intermittent over-engagement caused extreme tool wear
Material
1018 CRS
Tooling
3/8” (9.5mm) Solid Carbide 3 Flute Endmill
Spindle Speed
4,500 RPM
Depth of Cut
.25” (6.35mm)
Feedrate
30” ipm (762 mmpm)
Chip Load
.002” (.050mm)
Cycle Run Time
11 Minutes, 16 Seconds
Notice the “Racetrack” toolpath pattern, resulting in sharp corners throughout the pocket
Feedrates, RPM, and Depth of Cut are all limited in traditional machining toolpaths due to the increased linear forces against the tool – especially in the corners
Intermittent over-engagement of the tool caused extreme wear – must be changed after EACH part. Also, due to the .25” DOC, only the tip of the tool is damaged

8. Traditional Process vs. HSM
HSM Processing
Much different toolpath pattern – NO sharp corners
DOC, Feedrates, and RPM dramatically increased
No noticeable wear on the tool – tool will last thru several parts
Material
1018 CRS
Tooling
3/8” (9.5mm) Solid Carbide 3 Flute Endmill
Spindle Speed
12,000 RPM
Depth of Cut
.625” (15.875mm) …FULL DEPTH
Feedrate
157 – 285 ipm (3987 – 7238 mmpm)
Chip Thickness
.0033” (.0838mm)
Cycle Run Time
2 Minutes, 51 Seconds
Much different toolpath pattern, that results in NO sharp corners – reducing or eliminating the linear forces on the tool
DOC, Feedrates, and RPM can be increased dramatically
No noticeable wear on the tool after competing the part
The reduction in linear forces on the tool will allow the tool to be utilized in multiple parts – therefore reducing the tooling cost per part

9. Traditional Process vs. HSM
High Speed Machining 2:51

10. 33% faster spindle – feedrates can be increased
Standard Spindle - 12,000 RPM
Same HSM processing strategy, depth of cut, chip thickness, and tooling
33% faster spindle – feedrates can be increased
Depending on geometry, UltiMotion could be even faster
Material
1018 CRS
Tooling
3/8” (9.5mm) Solid Carbide 3 Flute Endmill
Spindle Speed
12,000 RPM
Depth of Cut
.625” (15.875mm) …FULL DEPTH
Feedrate
157 – 285 ipm (3987 – 7238 mmpm)
Chip Thickness
.0033” (.0838mm)
Cycle Run Time
2 Minutes, 51 Seconds
18k = 33% Faster
Spindle Speed
18,000 RPM
Cycle Run Time
1 Minute, 54 Seconds
Same HSM processing strategy, Depth of Cut, Chip Thickness and tooling
Utilizing the 33% increase in spindle speed of the HS machine – feedrates could increase with the faster spindle
Depending on geometry this could possibly be even faster with UltiMotion – standard feature on HS machines

11. Show me the money Traditional Processing (12K)
High Speed Machining (12K)
High Speed Machining (18K)
Hourly Shop Rate
$60.00
Hourly Burden Rate
$35.00
Cycle Time
11 min : 16 sec
2 min : 51 sec
1 min : 54 sec
Cost to Produce
$6.57
$1.67
$1.11
Quoted Price
$13.50
Profit per Part
$6.93
$11.83
$12.39
Profit x 100 pieces
$693.00
$1,183.00
$1,239.00
Profit x 500 pieces
$3,465.00
$5,915.00
$6,195.00

12. 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
The faster you cut, the more blocks the controller needs to look ahead to plan the smoothest, fastest trajectory
Hurco’s proprietary Dynamic Variable Look Ahead – dynamically changes how far it looks ahead depending on feedrate, block length, and desired toolpath – up to 10,000
UltiMotion is predictive, and provides improved control of velocity and acceleration profiles based on upcoming obstacles
Guarantees look ahead is always adequate enough for upcoming maneuvers – allowing the control to determine the necessary output to the servo drives & motors

13. UltiMotion Exact same HSM program 29% cycle time reduction
Improved surface finish quality
UltiMotion
Standard Motion