What is high-speed CNC machining and its advantages in mass-producing customized parts?
- What is high-speed CNC machining and its advantages in mass-producing customized parts?
- What is high-speed CNC machining?
- How HSM works
- Difference between high-speed CNC machining centers and ordinary CNC machining centers
- Advanced technological advantages of high-speed CNC machining
- Advantages of high-speed CNC machining
- Simplify CNC machining process
- Achieving ultra-precision parts tolerance machining
- Precision machining of heat-deformed parts
- High processing speed makes it suitable for manufacturing large batches of precision parts.
- It can improve the final machining effect of precision parts.
- Hybrid processing technology can be achieved
- Integration of high-speed CNC manufacturing with Industry 4.0
- high-speed CNC machining equipment and ordinary equipment
- The core advantages of high-speed CNC machining for manufacturing batches of complex parts
- High-speed machining shortens the manufacturing time for batches of complex parts.
- High-speed CNC machining of parts with high tolerance requirements has high production efficiency.
- High-speed machining can produce high-quality part surfaces.
- It can simplify the machining process of complex parts (such as impellers).
- High-speed cutting can machine hard metal parts with complex shapes.
- Choose Elimold as your partner for high-speed CNC machining services
- in conclusion
High-speed CNC machining is a manufacturing technology that operates on the same principle as conventional CNC machining, differing only in spindle speed. Initially developed for the aerospace industry to improve cutting speed, efficiency, and dimensional accuracy, it is now being used in other industries such as automotive, medical, machinery, and electronics manufacturing. This technology can shorten processing cycles and increase efficiency without compromising product quality.
High-speed machining (HSM) offers a combination of speed, precision, and efficiency, achieving higher metal removal rates with shorter milling strokes, higher feed rates, and higher spindle speeds. Therefore, the advantages of high-speed CNC machining are significant. Moreover, the advantages of high-speed CNC machining stem primarily from the challenge that conventional CNC equipment often faces in maintaining speed and precision during machining. Traditional methods generate excessive heat, leading to tool wear, reduced accuracy, and ultimately, inefficiency. High-speed machining (HSM) provides a solution by employing advanced technology combined with high spindle speeds and feed rates. This method minimizes heat generation and wear while ensuring precise cuts and smoother surfaces. By adopting HSM, manufacturers can reduce production time, improve overall product quality, and enhance operational efficiency.
What is high-speed CNC machining?
While there is no explicit definition for high-speed CNC machining, machining experts describe it as the process of manufacturing metal parts with high precision. It utilizes high spindle speeds and feed rates to remove material from parts without compromising their quality and dimensional accuracy. HSM is typically integrated into most computer-aided manufacturing (CAM) software systems. To make machining faster, easier, more efficient, and to minimize errors, high-speed machining (HSM) combines equipment, tools, and software to outperform traditional machining methods. High-speed machining is ideal for producing prototypes, machining complex parts, and producing small batches of components.
How HSM works
High-speed machining (HSM) is a process that removes material quickly and precisely using high spindle speeds and feed rates. Unlike traditional machining, which typically involves slower, heavier cuts, HSM uses lighter, faster cutting speeds to achieve high precision while minimizing heat and tool wear. The significantly increased spindle speeds in HSM enable faster material removal and smoother surfaces. CNC and CAM technologies enhance this process, allowing for precise control of tool movement to ensure efficiency and accuracy. CNC programming supports real-time adjustments to optimize speed and feed rates, making HSM ideal for the rapid and efficient production of complex parts.
Difference between high-speed CNC machining centers and ordinary CNC machining centers
High-speed CNC machining centers are redesigned versions of conventional CNC machining centers. The key difference lies in their significantly higher rotational speed and rapid displacement speed, along with numerous adjustments and optimizations to their mechanical structure. So why is there a market demand for high-speed CNC machining centers? The primary reason is the increasing demand from CNC machining service providers for precision and complex parts, driving CNC machining equipment R&D companies to develop and promote these technologies.
Understanding the difference between the two types of equipment is quite simple. The spindle speed of a standard CNC machining center is typically around 8000 rpm, while high-speed CNC machining centers reach 12000 rpm or 15000 rpm. This is the fundamental difference: the higher the spindle speed, the higher the precision of the machined product. Another important aspect is the rapid displacement speed. High spindle speed must be combined with rapid displacement to achieve its high-speed effect, and the rapid displacement speed is also a direct factor affecting product processing efficiency. Standard CNC machining centers generally have a rapid displacement of 24 m, while high-speed CNC machining centers reach 36 m or 48 m. This is more than twice as fast as standard CNC machining centers, which determines the processing efficiency.
High-speed CNC machining centers are typically used for high-precision product processing, such as aluminum alloy products and lightweight products like mobile phone accessories. As product quality improves across various industries, the application areas of high-speed CNC machining centers will become increasingly widespread.
Advanced technological advantages of high-speed CNC machining
Experienced professionals utilize a variety of techniques in high-speed machining. The following are the main methods commonly used in various CNC machining projects:
cycloidal milling
This machining method produces grooves wider than the cutting diameter of the tool. It uses a series of circular cuts (also known as trochoidal toolpaths) to maintain a constant chip thickness. It is best suited for milling deep grooves or recesses, narrow channels and cavities, and performs well on hard materials such as titanium and Inconel alloys. Trochoidal machining is also popular because it can accurately read the machining cycle and maintain a constant feed rate.
roughing
Straight-in roughing is a machining technique in which the tool cuts directly into the material. The tool removes a large amount of material rapidly at a high feed rate. Straight-in roughing is ideal for applications requiring the machining of deep cavities and large tool deflections, and is one of the most efficient CNC machining processes.
Sidestep
At higher feed rates, lateral machining can create effective toolpaths between adjacent paths. It allows for sharp turns between sweep paths at high feed rates. Lateral machining smooths out sharp turns and achieves more rounded movements at high feed rates. While simple “circular” toolpaths can achieve the same effect, they are only effective at medium feed rates.
Advantages of high-speed CNC machining
High-speed CNC machining offers numerous advantages over traditional machining methods. It utilizes higher spindle speeds and feed rates, enabling rapid cutting, minimizing heat transfer and workshop emissions, among many other benefits. The main advantages of high-speed CNC machining are as follows:
Simplify CNC machining process
The high-speed CNC machining technology used in the manufacturing of customized complex parts not only simplifies the production process but also allows for the selection of production equipment with appropriate precision as needed. This reduces the overall number of cuts and, because this technology generally avoids surface hardening issues in parts, effectively shortens the production process, reduces the number of steps, and consequently reduces the production cycle and costs.
Achieving ultra-precision parts tolerance machining
Because CNC high-speed machining technology offers considerable cutting speeds, its total cutting parameters can be appropriately and uniformly reduced by less than 30%, especially the radial cutting parameters, which are significantly reduced. This meets the technical requirements for machining thin-walled and low-rigidity parts. Generally speaking, the overall system accuracy of CNC high-speed cutting is good because the clamping accuracy and workpiece positioning accuracy of the entire system have good precision retention characteristics. Therefore, the overall precision requirements of the tools in the entire control system are correspondingly high, ensuring the overall dynamic and static performance of the entire control system during high-speed cutting, thereby achieving high tolerances and meeting the requirements of precision parts machining.
Precision machining of heat-deformed parts
In the production process of high-speed CNC machining equipment, generally 95% to 98% or even more of the cutting heat is not transferred to the workpiece in time and is carried away by the chips, causing the workpiece to remain in a cold state for many hours. Therefore, this process is more effective for some parts that are prone to thermal deformation.
High processing speed makes it suitable for manufacturing large batches of precision parts.
While conventional CNC equipment typically cannot improve machining efficiency, advanced machining processes using high-speed CNC machining equipment can ensure the highest cutting speed. Its overall performance also exceeds the cutting speed range of conventional CNC equipment. Compared with conventional equipment, the machining efficiency of this advanced equipment can be 5 to 8 times higher. This not only reduces the number of non-mechanical processing and idle runs of the machine equipment, but also enables the rapid production of large quantities of precision parts, thus fundamentally achieving a balance between machining time and machining accuracy.
It can improve the final machining effect of precision parts.
Generally, conventional CNC machining equipment presents relatively high challenges in manufacturing aluminum-magnesium alloy parts. These parts exhibit high hardness and tensile strength, but due to their combined high temperature and erosion resistance, there is a significant likelihood of thermohardening during processing. This can lead to extremely high cutting temperatures, which over time can easily cause tool wear, compromising tool lifespan and overall quality. However, applying high-speed CNC cutting methods not only effectively solves these technological difficulties but also ensures a balance between efficiency and quality in mechanical manufacturing.
Hybrid processing technology can be achieved
High-speed CNC machining equipment enables hybrid processing using both conventional and high-speed methods. This approach combines high-speed machining (HSM) with advanced processes such as additive manufacturing or laser cutting. This integration enhances production flexibility, allowing manufacturers to fully leverage the advantages of multiple technologies within a single workflow. By combining HSM with these processes, manufacturers can achieve greater precision and efficiency, particularly when dealing with complex geometries or material properties that benefit from a combination of subtractive and additive manufacturing methods.
Integration of high-speed CNC manufacturing with Industry 4.0
The convergence of artificial intelligence, machine learning, and the Internet of Things (IoT) is transforming high-speed manufacturing through smart manufacturing. These technologies monitor real-time machine data, enabling instant adjustments to optimize performance. Predictive maintenance powered by AI and IoT can detect potential problems before they cause machine downtime, further increasing productivity. Real-time performance analytics helps manufacturers maximize efficiency and reduce errors, making smart manufacturing a key trend for the future of HSM.
high-speed CNC machining equipment and ordinary equipment
Experienced professionals utilize a variety of techniques in high-speed machining. The following are the main methods commonly used in various CNC machining projects:
cycloidal milling
This machining method produces grooves wider than the cutting diameter of the tool. It uses a series of circular cuts (also known as cycloidal toolpaths) to maintain a constant chip thickness. It is best suited for milling deep grooves or recesses, narrow channels and cavities, and performs well on hard materials such as titanium and Inconel alloys. Cycloidal machining is also popular because it can accurately read the machining cycle and maintain a constant feed rate. Ordinary equipment cannot perform the above operations because it cannot guarantee the tolerance level of the final part.
roughing
Straight-in roughing is a machining technique where the tool cuts directly into the material. The tool removes a large amount of material rapidly at a high feed rate. Straight-in roughing is ideal for applications requiring deep cavities and large tool deflections, and is one of the most efficient CNC machining processes. Conventional equipment, on the other hand, can only perform low-deflection machining.
Sidestep
At higher feed rates, lateral machining creates efficient toolpaths between adjacent paths. It allows for sharp turns between sweep paths at high feed rates. Lateral machining smooths out sharp turns and achieves more rounded movements at high feed rates. While simple “circular” toolpaths can achieve the same effect, they are only effective at medium feed rates. Ordinary equipment cannot achieve this type of machining effect.
The core advantages of high-speed CNC machining for manufacturing batches of complex parts
High-speed machining offers numerous key advantages for manufacturing large volumes of complex parts. This equipment can increase spindle speed and shorten machining time, contributing to improved productivity and machining accuracy. These advantages, coupled with longer tool life and higher material efficiency, make high-speed machining the preferred choice for many manufacturers producing large volumes of complex parts.
High-speed machining shortens the manufacturing time for batches of complex parts.
High-speed machining uses cutting speeds approximately 10 times higher than conventional cutting to process complex parts. Because the excitation frequency of the high-speed machine tool spindle far exceeds the natural frequency range of the “machine tool-tool-workpiece” system, the parts are machined smoothly and without impact. Therefore, when manufacturing large quantities of complex parts, the manufacturing time of projects can be shortened.
High-speed CNC machining of parts with high tolerance requirements has high production efficiency.
When machining complex parts with high tolerance requirements using high-speed machining centers or high-speed milling machines, roughing and finishing of the profile and machining of other parts of the part can be completed in a single workpiece setup, a technique known as “one-pass machining.” The application of high-speed CNC machining technology has greatly improved the development speed of complex parts.
High-speed machining can produce high-quality part surfaces.
Due to the use of extremely small step distances and depths of cut, high-speed machining can achieve very high surface quality of parts, and may even eliminate the need for post-processing steps.
It can simplify the machining process of complex parts (such as impellers).
Previously, complex parts could only be manufactured using ordinary CNC equipment, which was not only slow but also resulted in inconsistent quality and a high scrap rate. Now, they can be manufactured using high-speed machining equipment, and the surface hardening caused by overheating of the workpiece is avoided. In addition, due to the reduction in cutting volume, high-speed machining can use smaller diameter tools to process smaller fillet radii and part details, saving some machining or manual finishing steps and thus shortening the production cycle.
High-speed cutting can machine hard metal parts with complex shapes.
As can be seen from the principle of high-speed CNC equipment, the cutting force is greatly reduced during cutting, and the cutting process becomes easier. High-speed cutting has a great advantage in cutting high-strength and high-hardness materials, and can process complex parts with complex surfaces and high hardness in batches.
Choose Elimold as your partner for high-speed CNC machining services
Elimold, located in Shenzhen, China, is a manufacturer specializing in custom CNC machined parts. With our range of high-speed CNC equipment, we are able to produce dimensionally precise, aesthetically pleasing products and parts. We serve industries including aerospace, electronics, military, and defense.
Whether you need parts for mass production or small-batch production, our high-speed CNC machining services are efficient and precise, enabling you to quickly complete complex machining tasks and achieve a high return on investment. In addition to CNC milling, we also offer MIM, die casting, and injection molding services to produce the custom parts you require.
At Elimold, we are committed to providing services that exceed our clients’ expectations. Therefore, we listen to your needs and expectations and do everything within our power to ensure your satisfaction 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.
in conclusion
High-speed CNC machining offers significant advantages, such as increased productivity, accuracy, surface finish, tool life, and energy efficiency. It also reduces material waste and supports greater levels of manufacturing automation. These advantages make HSM an indispensable tool for industries pursuing high-quality, high-efficiency production. In the long run, efficiency, reduced waste, and shorter production cycles not only bring the benefits of faster time-to-market and rapid product validation, but for CNC machining service providers like Elimold, they not only improve manufacturing efficiency but also help optimize processes and product quality, thereby maintaining competitiveness. If you have projects with highly complex part designs that require manufacturing using high-speed CNC machining equipment, please contact the Elimold team for assistance.