Analysis of the technical principles, advantages, processes and applications of high speed milling

As the manufacturing industry develops towards high efficiency and precision, high speed milling, as an emerging high-efficiency processing technology, has been widely used in the fields of aviation, automobiles, mold manufacturing and precision instruments with its excellent processing capabilities.

High speed milling can not only improve processing efficiency, but also optimize processing quality, but its realization does not rely solely on the increase in equipment speed. This article will introduce the technical principles of high speed milling in detail, analyze its advantages in the processing process, and explore how to make full use of this technology to improve productivity.

1. Definition and basic principles of high speed milling

High speed milling refers to a technology for milling at a higher spindle speed. Usually, the spindle speed of high speed milling is more than twice that of traditional milling. Its basic characteristics are to increase the speed, feed rate and reduce the cutting depth to achieve the purpose of improving cutting efficiency, reducing processing costs and improving processing accuracy.

The working principle of high speed milling mainly relies on the combination strategy of "high-speed cutting + small cutting depth + high feed". Under this process, the cutting force is relatively small, the friction between the tool and the workpiece is reduced, and the cutting temperature can be controlled within a reasonable range, thereby reducing the risk of thermal deformation and tool wear.

2. Analysis of the advantages of high speed milling

With the continuous development of processing technology, high speed milling has gradually become one of the indispensable processing technologies in modern manufacturing due to its many advantages. Below we will analyze several major advantages of high speed milling in detail.

(1) Improve processing efficiency

One of the biggest advantages of high speed milling is that it greatly improves processing efficiency. In traditional milling, due to the large cutting depth, the contact time between the tool and the workpiece is long, resulting in large cutting forces and high cutting temperatures. In high speed milling, due to the use of a smaller cutting depth and a higher feed rate, the contact time between the tool and the workpiece can be effectively reduced, thereby increasing the processing speed. In addition, the high speed of high speed milling can also effectively shorten the processing time of a single piece, especially in the mass production of complex parts, the efficiency advantage is more obvious.

(2) Improve processing quality

During the high speed milling process, due to the small cutting force and small vibration amplitude of the tool, the surface quality of the workpiece is significantly improved. Especially in precision machining, high speed milling can effectively reduce burrs, tool marks and surface roughness during machining. High speed milling can also significantly improve the dimensional accuracy of the workpiece, reduce machining errors, and ensure the high precision requirements of parts.

(3) Reduce tool wear

The low cutting depth and high speed in high speed milling help reduce the friction between the tool and the workpiece, reduce the accumulation of cutting heat, and thus extend the service life of the tool. Compared with traditional milling, high speed milling can effectively reduce tool wear, especially when processing hard materials, the tool life advantage is particularly obvious.

(4) Reduce thermal deformation

In traditional milling, excessive cutting depth and low cutting speed are prone to excessive cutting temperature, resulting in thermal deformation of the workpiece and affecting the processing accuracy. High speed milling effectively controls the increase in cutting temperature through high speed and small cutting depth, reducing the impact of thermal deformation on processing accuracy, especially when processing high-precision parts.

(5) Expand material adaptability

During the high speed milling process, the temperature of the tool rises slowly, which can better adapt to the processing requirements of materials such as cemented carbide, titanium alloy, and graphite. Especially in the aviation and aerospace industries, the processing of complex alloy materials and superhard materials has become the norm, and the high efficiency and precision performance of high speed milling can meet the processing requirements of these materials.

3. High speed milling process and steps

High speed milling is an efficient and high-precision processing technology that involves multiple links. The following are the main processes and steps of high speed milling:

(1) Workpiece preparation and fixture design

Workpiece selection and clamping: Select the appropriate material and confirm the size and shape of the workpiece. The workpiece should be clamped firmly to ensure that it will not loosen or vibrate during high-speed cutting, affecting the processing accuracy. High-rigidity fixture design can effectively ensure processing stability.

Fixture design: According to the complexity of the workpiece, select or customize the appropriate fixture to ensure that the workpiece is stably fixed, reduce vibration, and avoid affecting the processing effect.

(2) Tool selection and installation

Tool selection: Select a tool suitable for high speed milling, usually carbide or coated tools. The diameter, shape, coating, etc. of the tool should be selected according to the processing requirements to adapt to high speed, high feed and other conditions.

Tool installation: When installing the tool, ensure that it is aligned with the spindle to prevent unnecessary vibration and affect the processing accuracy. The tool must be firmly fixed to avoid offset or loosening.

(3) Processing parameter setting

Spindle speed setting: The key to high speed milling is to increase the spindle speed. The speed should be set reasonably according to the material and tool characteristics. Too low speed will affect the processing efficiency, while too high speed may cause increased tool wear.

Feed speed and cutting depth: Set the appropriate feed speed and cutting depth. In high speed milling, a smaller cutting depth and higher feed speed are usually used to ensure stable cutting force and balanced processing effect.

(4) High speed milling

Roughing: High speed milling can be used in the roughing stage to quickly remove most of the workpiece excess. At this time, the cutting temperature should be controlled to avoid affecting the processing accuracy due to excessive temperature.

Finishing: During finishing, a smaller cutting depth and higher feed speed are used to ensure high surface quality and lower error.

(5) Cutting fluid and cooling system

Cutting fluid selection: Cutting fluid is used to reduce cutting temperature, reduce tool wear and improve surface quality. The appropriate cutting fluid should be selected according to the processing material to ensure a stable processing environment.

Cooling system configuration: The high-pressure cooling system can reduce heat accumulation and protect the tool and workpiece by spraying cutting fluid to the contact area between the tool and the workpiece.

(6) Monitoring and adjustment

Real-time monitoring: Use sensors to monitor key parameters such as tool wear, cutting force, and temperature. When abnormalities are found, the processing parameters need to be adjusted in time.

Process adjustment: According to real-time feedback, adjust the spindle speed, feed speed, etc. to optimize the processing effect and ensure processing accuracy and tool life.

(7) Post-processing and quality inspection

Surface quality inspection: After processing, check the surface finish, dimensional accuracy and other quality indicators of the workpiece to ensure that they meet the design requirements.

Tool inspection and replacement: Check the wear of the tool and replace or re-grind it if necessary to ensure processing quality.

4. Application fields of high speed milling

Due to its unique advantages, high speed milling has been widely used in many fields, especially in industries with high requirements for processing accuracy and efficiency, and plays an irreplaceable role.

(1) Aerospace

The aerospace industry has extremely high requirements for the accuracy and quality of parts. High speed milling technology can greatly improve processing efficiency while ensuring high accuracy, especially in the processing of complex aviation parts, it can achieve high precision and high surface quality requirements.

(2) Mold manufacturing

Most parts in mold manufacturing have complex geometric shapes and require high-precision processing. High speed milling can efficiently process complex mold cavities while maintaining low cutting forces, avoiding mold deformation, and increasing the service life of the mold.

(3) Precision machining

Precision instruments and equipment parts require extremely high processing accuracy. High speed milling can effectively improve the surface quality and dimensional accuracy of these precision parts and is widely used in medical equipment, optical equipment, measuring instruments and other fields.

(4) Automobile manufacturing

In automobile manufacturing, high speed milling technology is mainly used for the processing of engine, transmission and body parts. Through high speed milling, production efficiency can be significantly improved, and high precision and high surface quality of parts can be guaranteed, meeting the dual requirements of the automotive industry for part quality and production efficiency.

5. Conclusion

High speed milling technology has gradually become an indispensable and important processing method in modern manufacturing due to its significant advantages such as high efficiency, high precision and low tool wear. From principle to practical application, every technical detail of high speed milling determines the improvement of processing efficiency and quality. It is hoped that the analysis in this article will help industry insiders better understand high speed milling technology and fully tap its potential in practical applications.