High-speed cutting (HSC) has long been considered synonymous with high-speed production and processing for almost two decades. Today, people's attention is increasingly focused on the new term HPC (high productivity cutting or high performance cutting).
Figure 1 Measuring cutting force when using a formed and non-formed tool cutting edge
What is HPC milling?
In general, HPC milling is described as milling that meets the requirements for improved metal removal rates, a key technical measure that determines the performance potential of a process, which is 200% to 500% higher than conventional machining techniques. The broader explanation is that the term HPC also means optimizing the entire process chain with the goal of reducing production costs by 10% to 30%.
What is the difference between HPC and HSC?
The purpose of roughing is to maximize the metal removal rate: due to the fact that the 3D surface is processed regardless of the increase of axial or radial feed, it will be seriously restricted by HSC technology. To improve the processing rate, only by increasing Cutting speed is gone. However, there will be other practical and technical constraints.
Increasing the amount of axial and radial pockets and increasing the feed rate (increasing the speed of vf does not necessarily increase the cutting speed of the HSC) should help improve machining efficiency.
On the one hand, one result of these milling processes is that they are comparable in efficiency to conventional milling. On the other hand, increasing the feed rate at a certain cutting speed results in an increase in the feed rate per tooth of the tool, thus increasing the mechanical load on the milling cutter. Regardless of the geometry of the selected cutting edge and the tool material, a relatively high cutting force is produced during machining, which in turn increases the requirements for the machine's working environment.
Figure 2 Wear evolution of formed and non-formed tool cutting edges
Based on this background, the main question raised is whether the high-cutting roughing tool should use different blade geometries.
High-performance cutting force and wear phenomena generated <br> <br> We conducted a lot of experiments to determine the effects of different shapes on the cutting edge in the process of cutting force. Figure 1 shows the corresponding curves of a cutting force curve under fixed conditions and a tool with a smooth cutting edge after milling with a contoured tool for 10 seconds.
If the arithmetic mean cutting force of the two tools is set, it can be determined by experiment that the cutting force of the contoured tool is reduced by 23.5%. In order to maximize the use of spindle output power, designing HPC roughing cutters with contoured cutting edges seems to be an excellent choice.
In addition to high-speed metal cutting and optimized spindle spindle power requirements, tool life is also a key factor in the economics of milling.
Figure 2 shows the representative wear phenomena of these two types of knives. After a very short period of time, there is local chipping on the contoured carbide cutting edge, especially in the contoured areas. The high feed rate and the large number of knives in HPC milling, combined with the reduced lateral support of the cutting edges on the contoured contours, are reduced beyond the rigid limits of today's most advanced particulate carbide metal quality. Produces great mechanical loads.
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