High-speed CNC machining is an innovative concept revolutionizing the manufacturing industry. It was initially employed in the aerospace industry to increase cutting speeds, efficiency and dimensional material accuracy. Other industries, such as the automotive, medical and electronic manufacturing industries, now also use high-speed machining to reduce cycle times and increase efficiency without compromising quality.
High-speed machining (HSM) combines speed, precision and efficiency to achieve a high metal removal rate with lighter milling passes, high feed rates and spindle speeds. As a result, the advantages of rapid CNC machining are far-reaching. Below, we discuss the main techniques in high-speed CNC machining and the benefits of this machining technique.
There’s no concrete definition of high-speed CNC machining. However, machining experts describe it as the process of creating metal parts with high accuracy and precision. It uses high spindle speeds and feed rates to remove material from a part without compromising its quality and dimensional precision.
HSM is often integrated into most computer-aided manufacturing (CAM) software to make machining faster and easier, increase processing efficiency and minimize margins of error. It’s enabled by a combination of equipment, tooling and software, which makes it superior to traditional machining methods. HSM is an ideal method for producing prototypes, complex part machining and small-batch components.
Experienced professionals use several techniques in high-speed machining. Here are the top methods employed in various CNC machining projects:
This machining method creates slots wider than the cutting tool’s cutting diameter. It uses a series of circular cuts, also known as trochoidal tool paths, to maintain constant chip thickness.
It’s best used for milling deep pockets or recesses, confined grooves and cavities and works well with hard materials like titanium and Inconel. Trochoidal machining is also popular for reading cycle times and maintaining constant feed rates.
Plunge roughing is a machining technique that plunges the tool directly into the material. The tool quickly removes large amounts of material at a high feed rate. Plunge roughing is ideal for applications that require the generation of deep pockets and more tool deflection and is one of the most efficient CNC machining processes.
When feed rates are high, side-step machining creates effective tool paths between adjacent paths. It allows sharp turns between scan passes at high feed rates. Side steps smooth the sharp transitions and more rounded moves when the feed rates are high. This could be accomplished by using simple “looping” tool paths, but they’re only effective at moderate feed rates.
High-speed CNC machining has many benefits over traditional machining methods. The higher speed and feed rate employed in HSM result in rapid cutting, minimal heat transfer and decreased shop emissions, along with numerous other advantages. These are the main benefits of rapid CNC machining:
High-speed machining can extend the life span of CNC equipment by reducing the stress applied to the machine and the cutting tool. Unlike traditional machining tools, high-speed mills with minimal wear on the cutting edge minimize the need for sharpening and replacement. As a result, operators can continue to use the same CNC equipment without needing to make premature replacements or repairs.
Rapid machining is attractive to many manufacturers because it reduces turnaround time due to the increased spindle speeds and feed rates. This process produces minimal heat, reducing the time needed for the material to cool and harden, leading to minimized production times. Improving productivity with high-speed CNC machining minimizes the overall costs of manufacturing parts and decreases cycle times.
This machining process allows higher repeatability, meaning you can accurately reproduce multiple pieces with high tolerances without human intervention. This saves turnaround and operator time by streamlining the manufacturing process and allowing the production of multiple workpieces simultaneously.
With high-speed machining, you can produce high-quality parts with superior dimensional accuracy. The high-speed spindle removes materials from parts more precisely to create better dimensional accuracy and superior surface smoothness. Cutting at high speeds produces less heat, minimizing the risk of deflection or part deterioration.
Dimensional accuracy is especially important when working with harder metals, parts with thin walls and smoother surface finishes. Rapid CNC machines create highly tolerable parts because they use precise instructions from software, and a computer controls all of the movements. This eliminates human error and enables repeatability in the production chain.
Because the spindle moves at high speeds, there’s minimal heat exchange, cutting forces and vibrations between the chip and the machined part. As a result, the part doesn’t undergo unintended structural changes, maintaining its quality and integrity.
Using advanced computer controls to guide the cutting tool minimizes waste by making more precise cuts, thereby minimizing the amount of faulty or damaged parts that need to be discarded during manufacturing. Producing smooth and visually appealing surfaces reduces the need for additional finishing processes.
Rapid machining or milling produces products more quickly and efficiently than traditional methods. Additionally, it creates greater consistency by allowing the repeatability of results, significantly reducing setup times. Automation also leads to greater efficiency because processes can be completed faster than when using manual methods.
Because CNC machines work fast, they draw less power per minute, use fewer materials and reduce margins of errors. Improving efficiency and productivity helps manufacturers save money, meet deadlines and scale their businesses.
Based in Chambersburg, Pennsylvania, American Micro Industries is a custom manufacturer of CNC machined parts made from non-metallic materials, such as electrical insulators and high-density foams. With our range of high-speed CNC milling machines, we can create dimensionally accurate and visually pleasing products and parts. Some of the industries we serve include aerospace, electronics, military and defense.
No matter if you require mass-produced parts or short-run parts, our CNC machining services are efficient and precise, quickly producing complex work to help you get a high return on your investment. Apart from CNC machine milling, we offer die cutting, laser cutting and other services that can produce the made-to-order components you require.
At AMI, we aim to go above and beyond for our customers, so we’ll listen to your needs and expectations and do everything within our scope to ensure you’re satisfied with our products and services. Contact us today to learn more about our high-speed CNC machining services. Ready to get started? Request a quote to begin the process.
