Keynote Paper

High-Speed Machining
Herbert Schulz (1), Technical University of Darmstadt/Germany; Toshimichi Moriwaki (1), Kobe University/Japan

Abstract
The high speed machining is now recognized as one of the key manufacturing technologies for higher productivity and
throughput. The papar reviews recent development in high speed machining and related technology especially in the last
decade. The state of the art of high speed cutting, cutting tools and machine tools for high speed cutting are presented.
The realization of hsc demands new unconventional solutions for machine tools and their components. The optimization
and the safety precautions of the tools are very important. nme reduction of more than 50% can be achieved.

Keywords: high-speed cutting, hsc-machine tools, cutting tools

Acknowledgement
This papar was jointly prepared by the members of STC ·e•and STC "M" demands for high speed machining of light metais, such as aluminum, are
to provida information of the state of the art of high speed machining increasing not orily in the aircraft industries, but also in electric and
technology. The authors would like to express their sincera gratitude to the electronics industries. The interests in recent research and development
members listed below for their valuable contribution to prepare the papar: are directed to high speed and high throughput machining oi difficult-to-
R. Komanduri, Oklahoma State University machine materiais, such as nickel-based ailoys for air craft engines and
R. Levi, Politechnico di Torino ferrous alloys for dies. Another target material is graphite which is used as
T. Nakagawa, The University of Tokyo the elctrode for EDM to manufacture dies.
K. Nakayama, Toyama Prefectural University
Drilling, as well as milling and turning, is recognized as a process to be
V.C. Venkatesh, Tennessee Technological University
accelerated /27, 32/. The cutting speed in drilling has been drastically
J. Vigneau, SNECMA
increased in the last decade owing to recent development in drill geometry
lt is also to be noted that information and data concerning practical
suited for high speed drilling /7, 21, 66/.
applications of high speed machining were provided by industries in Japan
and Europa. The definition of high speed cutting is not easy, since the actual cutting
speed that can be achieved depends upon the work material, lhe type of
cutting operation, the cutting tool used etc.. Thus, the definition of high
speed cutting or ultra-high speed cutting changes depending on the
1. lntroduction
technologies available /72, 75, 85/. The range of cutting speed for high
High speed machining or more specifically high speed cutting has been
speed milling at present is summarized in fig. 1.
attracting il)terests of manufacturing scientists and engi"eers for many
years. ln 1978, CIRP Keynote Papar "High Speed Machining Possibilities
and Needs" was produced by J. F. Kahles, M. Field and S. M. Harvey who pibloesrli------ -HSM-rorge
reviewed the status of high speed machining based on the international cs
-lrmsilim1e1Jim
survey of CIRP members and others from industry /29/. They reported that limnium
twenty-six research labs, ali over the wortd were investigating this subject.
They also made an additional report at 1982 CIRP General Assembly tronze
which was mainly focused to practical application of high speed machining IJ"oss
in the U.S.A. /10/. The present papar surveys the development in the cosi too
relevant fields mainly in the last decade and focuses on the present state
of the art of high speed machining technology.
sleel
The major objectives of high speed machining research are classified into
three categorias. The first, pursued in the early stage of research, was the lilcnum
technologicai breakthrough in machining of titanium and steel alloys, which nickel-lxlse
was not successful so far. The second is the improvement in surface Fig. 1:
quality and machining accuracy, which has been successful in some cases olloys Cutting speeds
such as finish cutting of aluminum. The third is aimed at very practical goal 10 IX) 11111 1M1J1JJ 1)(111
forhsm
of achieving higher productivity or throughput in machining various culling speed v, -
materiais. The interests of researchers and engineers have been shifting to
this goal in recent years /92,46/: The cutting technology is lhe basis for the development oi ali components
involved in the high speed cutting (hsc) process.
One of the most systematic researches on high speed machining is lhe 4- This means that lhe material-specific cutting technology not only influences
year Advanced Machinining Research Program (AMRP) sponsored by the development of tools, but in a special way the design and the
Defense Advanced Research Project Agency (DARPA) started in 1979 in components of the machine tools, as well as the specific cutting process
the U.S.A, which was aimed to provida a science base for faster metal itsell (fig.2).
remova! through high speed machining and laser assisted machining. The
emphasis was placed on tuming and milling of aluminum-, nickel-based·,
titanium- and lerrous alloys. The experimental cutting speed ranged lrom
0.0013 m/min to 24,500 m/min. Some of the results were published in
"High Speed Machining" edited by R. Komanduri, K. Subramanian and B.
F. von Turkovich, published by ASME /44/. The book also contains various
contributions related to lhe high speed machining ai that time.
ln Germany lhe researches on hsc were deeply supported by lhe Ministry
of Research and Technology (BMFT). Two joint research projects under
lhe leadership of the lnstitute of Production Engineering and Machine
Tools (PTW) of lhe Technical University Darmstadt were sponsored by the
BMFT and lhe industry. ln the first project, 1979-1983, a motorspindle with
active magnetic bearings had been developed and its application on high
speed milling of aluminum alloys had been investigated. ln lhe second
one, 1984-1988, "high speed milling of lerrous and non-ferrous materiais",
in which 41 companies participated, the research not only concentrates on
the hsc-technology but also deeply in hsc-tools, machine tools and their
main components, hsc-processing, efficiency and application. The results
were published in lhe book by H. Schulz /72/.
Researches up to now have been continued worldwide mainly lrom lhe
viewpoint oi cutting mechanics /41, 42, 43, 45, 47, 49, 51, 73, 81/, cutting Fig. 2: Relationship between cutting technology and rnachine tools
tools /25, 37, 60, 86, 89, 90, 91/ and machine tools /3, 9, 46, 82/. The

Annals ofthe CIRP Vol. 41/2/1992 637

2. Fundamentais of Hlgh Speed Cuttlng
2.1 Mechanlcs of Hlgh Speed Cuttlng
Results of various high speed cutting tests show that lhe mechanics of so-
called continuous chip formation applies to high speed or even ultra- high
speed cutting oi a metal or alloy oi bcc/fcc crystalline structure. high
thermal conductivity, and low hardness such as aluminum alloy or soft
low-carbon steel.
On the other hand, shear localization occurs with such materiais as
titanium alloys, nickel-based superalloys, and hardened alloy steels, which
are characterized by low thermal diffusivity, hexagonal, closepacked
crystalline structures, and high hardness /38/. lt occurs at all cutting
speeds in titanium alloys, while with other difficult-to-machine materiais it
occurs at speeds within and above a transition speed range which
depeneis on the material and its metallurgical condition /42, 43, 45/.
lt is now common understanding that the cutting temperature increases
with an increase in the cutting speed, and it does not decrease with a
further increase in the speed unlike famous prediction by Dr. C. Salomon
in 1929. J. F. McGee showed that the cutting termperature oi aluminum
increases monotonically with an increase in the cutting speed until it
reaches to the melting point oi the material /54/.
The cutting force decreases with an increase in the cutting speed due to
softening oi the work material ll4, 84/. lt is reported in some cases that the
cutting force reaches to minimum and increase with a further increase in
the cutting speed /44, 75/.
2.2 Advantages of Hlgh Speed Cuttlng
Apart from the increased productivity or throughput, high speed cutting
offers lhe following advantages over conventional cutting;
1) lncreased machining accuracy, especially in machining oi thin webs due
to reduced chip load,
2) Better surface linish and reduction in the damaged layer,
3) Reduced bur formation,
4) Better chip disposal,
5) Possibility oi higher stability in cutting due to stability lobes against
chatter vibration,
6) Simplified tooling, etc..
stress alises leading to longitudinal and transversa cracks, especially with
coated hard metais and cermets. With coated hard metais the hard
material layer in the cutting edge zone is removed alter a short application.
ln spi1e oi this the coating which reaches from lhe ,lace and flank into the
cutting zone acts as support and prevenis a rapid increase in flank and
facewear.
AI higher temperatures the nc- and TiN-hard matelials oi the cermets
have a lesser solubility than tungsten carbide, in respect to iron. Therefore
a higher chemical resistance against oxidation and diffusion is present
n21.
While using hard metais that lack heat-wear resistance rendering the
cutting material useless, oxid ceramic cutting materiais wear out because
oi their small tenacity and insufficient thermal shock resistance. Therefore
with these materiais, "break-outs• at the cutting edge can alise even at the
beginning oi a process. By reinforcing the oxidceramics wi1h SiC-whiskers
higher transverse breach resistance and fracture strength can be achieved
/60, 96/.
Using mixed ceramics (Al203-TIC) a smaller increase oi the width of wear
land is noted, while break outs oi the cutting edge occured early.
Silicon nitride has a comparably high bending strength and thermal shock
resistance. This can lead io a measurable increase oi tool life travei,
especially during machining with interrupted cuts /6/ (fig. 3).
When using EN 9 (0.6 % C) while lathing with three different ceramic
materiais lhe dominance of lhe diffusion wear at higher cutting speeds was
confirmed, which leads to a superproportional decrease of tool life travei
/19/.
Another possibility to increase the tenacity oi aluminum oxid ceramics is
the reinforcement with zirconic oxide grains (phase-transformation
inforcement). During the cooling process following the sinter operation the
Zr02 changes from the tetragonal to the monocline phase. This phase
does not transpire with fine-grained Zr02.
During the following grinding oi the ceramic a partia! phase transition
occurs on the surface oi the cutting material. Therefore compressive
strains result in the surface area oi the cutting material. ln contrast to SiC
Zr02 is reaction resistant to irori even at higher temperatures. The
Fig.3:
Wear properties oi different
cutting materiais while high
speed machining steel

2.3 Llmltatlons and Dlsadvantages of Hlgh Speed Cuttlng

For machining most of aluminum alloys, the maximum cutting speed is not li
limited by the life oi cutting tools, and the technology for high speed
machine tools is almost available in terms oi hardware and software. 5 Ck 45
culdown millirg -l-"<,---1'.,H- -H
However, lhe cutting speed is still limited by the tool wear in machining oi dry rui
the difficult-to-machine materiais, such as superalloys, titanium alloys, o,, 1.Snvn u • t6º+-1 Y+l
o,• Snvn , ,o•
hardened alloy steels etc..
t d '40m W.,.,U6nm
100 um mArw> 11m
One oi the possible limiting factors for future high speed cutting is the
culling speed v, - F,g.4:
momentum energy. When the workpiece is cut and the chip is generated, Wear properties oi CBN bali
additional energy has to be supplied to the cutting process in order to end cutter while machining
accelerate the chip past the shear zone. The energy associated with this quenched die steel (HRC 57)
momentum force is proportional to the power oi three of the cutting
speeds, while the cutting energy is basically in proportion to the cutting
f ll2 cutoown-nullrg
mm 1----\--..j-,..-.+---+,, -+- dry cul
speed. According to rough estimations, the momentum energy reaches

-
o,=O.Znrn
o 1p;Q)m/lM
about 10 % oi cutting energy at 10,000 m/min /59/, and it becomes almost 0.l l---\--,+--+-,,,,,.c+--+-----l t,,0.03
equal to the cutting energy at 30,000 m/min /38/.
O E •v.;;71JJm/m
3. Tools for Hlgh Speed Cuttlng i 6 Yc=Ml40m/mm
For high speed cutting tools 4 criteria are decisive: cutting alloy, cutting O Dl Iro m WJ 1, , 0.05
edge geometry, design and the interface between tool and machine cutling length 11 -
spindle.
favourable properties concerning the crater- and flank wear between
3.1 Cuttlng Alloys aluminum • zirconic • ceramics were observed during comparison cutting
Essential for the choice oi the right material is the knowledge of the wear tests oi C45 at 600 m/min with P10, Al203 and Al203-TIC /60/.
processes /50/. Wear by abrasion normally is dominant in conventional The use of CBN tools leads to sufficient tool life also in the machining oi
machining; while with hsc-cutting it remains in the background. Due to the quenched die steel (HRC 57) (fig. 4) /58/.
increased cutting temperatures caused by increased cutting speed,
diffusion wear and wear processes between workpiece and cutting edge High cutting speeds oi cast lron range between 750 and 4500 m/min
are dominant in hsc /2/. /40,48/. For the speed range up to 1250 m/min hard metal and cermets are
Coated and uncoated hard metais /2, 5, 67/, cermets /12, 61/, ceramics suitable as cutting materiais. ln the higher speed range one uses silicon
/26, 80, 87/ as well as polycristalline boron nitride /6/ are used for the hsc· nitride and cubical boron nitride (fig. 5) /35, 36, 63, 83, 881.
machining of steel.
For the uncoated hard metais the p-types are preferable because they 0.3
have higher shares oi titanium and tantal carbide. Compared to tungsten
carbide these carbides have a better heat- resistance to wear because of a
t -KlO
cc""' culdowon,ltirg
GG25
> drycut
lower avidity with steel /6, 68/. v,, Zllllm/11111
By coating hard metais it is P.OSSible to combine their relatively high OZN----1 ----- 1 1,,0.13 nm
endurance propenies with the wear characteristics oi the coating. o,: 10mm
nc-coatings enable a high resistance to flank wear while TiN-coatings P40 o,, 1.5mm
allow little crater wear /30/. Coatings with Al203 or ALON remain 3'
õ Ul 1-=-.L.---'-----1---
chemically stable even at high temperatures because oi their low avidity.
Multiple coatings with ALON show less crater wear; without ALON-
= I P40 cooli al K,.lO coo,l_ed
coatings a comparably smaller flank wear. These results were determined
F,g. 5:
by lathe tests at 247 m/min /67/. Wear properties oi
00'-- - - 1,c0.- - -z 0-'-- - ...3.01. ......................1.40--m Jso different cutting materiais
At higher cutting speeds high thermal shock stress in near-surface layers while high speed
oi the cutting material is evident. Therefore traction-pressure-altemating cutling length 11 - machining cast iron
Cermet shows a better tool life than hard metal because of higher edge materiais which consist of various structure components the hard material
strength, smaller adhesive tendency and higher chemical stability f72/. parlicles are washed out oi lhe binder phase because oi the strain during
During lhe turning process of cast iron the higher tool life oi ceramics lhe cutting process. Monocristalline cutting materiais tend to come off in
compared to the hard metal K15 is due to the thermal stability oi this splinters. With lhe use oi fine grained cutting materiais there are cutting
cutting material /62/. edge chamfers in addition to lhe flank wear. Only poly-cristalline diamond
For cutting peartitic cast iron, PKB-cutters are more advantageous than shows sufficient tool life at high cutting speeds (fig. 7) /64/.
SIALON-tools /11/. On the surfaces which were machined with PKB the
highest courseness value was 0.74 µm (Ra). Abrasion is the main problem concerning lhe hsc-machining of graphlte.
The high wear oi PKB during the machining of ferritic cast iron is notable. Therefore one gets lhe best results with PKD and PKB as abrasion
Already alter 0.5 minutes a 0.13 mm width oi wear land was measured ata resistant cutting materiais /33/.
cutting speed of 1800 m/min. While machining pear1itic cast iron under
equal conditions lhe width oi wear land was 0.071 mm. Possible causes 3.2 Cuttlng Edge Geometry
for this phenomenon are: a higher ductility oi the ferritic material, the ln arder to achieve sufficient tool life and low forces the cutting edge
high.er temperaturas on the conta<:'. zonas, the higher diffusion tendency oi geometry must be optimized. While an optimum effective cutting angle for
boron in ferrite or a combination of these three occurances. machining aluminum wrought alloys is 12· to 15', one shoL•ld choose a
During the machining of automobile brake discs an increase in productivity largar angle for cutting aluminum cast alloys (fig.8). ln the first case a dralt
from 150 pieces/edge with PKB to 3000 pieces/edge could be achieved by angle of 13· is especially appropriate, while in the second case, it should be
using silicon nitride /4/. 15·. Because oi the better chip removal an angle oi inclination between 20·
and 25' is recommended /31/.
Speclal alloys, for example, high alloy steels, titanium and nickel-based For lhe high speed cutting of steel an effective cutting angle of and a o·
alloys can only be cut with difficulty. dralt angle of 16' are recommended. Difficult-to-machine steels can be cut
With ceramics an increase of speed from 30 m/min to 200 m/min could be best with = y o·
and a = 20· /6/.
achieved while cutting nickel based alloys /43/. Cutting cast iron tools with an effective cutting angle oi and a dralt angle o·
For the roughening process SIALON and SiC-whisker reinforced aluminum oi 12· showed the best results /48/.
oxid ceramics are recommended and for the smoothing process the mixed For milling copper and copper alloys the best tools have an effective
ceramics. PKB is appropriate for both processes. Hard metais and cermets cutting angle of 8' and a dralt angle oi 16' /15/.
can be used as well, because cutting ceramics or PKB does not
Tools for machining fiber reinforced plastics have effective cutting angles
necessarily mean longer tool life travei /24/. largar than 20· and flank angles between 15· and 20· /64/.
High tool wear can cause problems while machining titanium alloys at
Negative effects on tool life are evident with the use of non-optimized
higher cutting speeds /45, 55, 57/. Because near1y ali cutting materiais cutting edge geometrias, as can be seen by the example oi lhe special
react with titanium alloys /97/, carbide and high-speed steel (HSS) are alloys (fig. 9) /24/.
normally used for machining this material. The knowledge of this problem
has lead to the development of a wear compensatíng tool, the so-called 150
AICuMgPb
ledge tool /40, 39/. t ...-+-'1,,_Q_16.,7 HM-KZO
.,. ..!L i---+--+--+---b"'"-
I= mm
Nowadays hsc-cutting is mainly used for llght metal alloys. ,a "• r--....._ ../" _ _,,,. 1,.QOl c:47\Z m/ml\
Among the hard metais lhe k-types demonstrate the best wear attributes 90 a=Jmm
because oi their high abrasiva resistance. Coating lhe hard metal only .§' '· f'---. -·· _" i--·...,....· _. fz=lmm
a.=13'
A, 25'
"5
effects an insignificant increase oi the wear properties (fig.6). Oxid ceramic
is not appropriate because the intensified strain caused by the interrupted
cut leads to edge break outs even alter a short period oi time 71/. no, 1 u 60
JO -- ·- -... ..-.. ... -·
-::.- fr=D.067
1.-0.033
d =S0tml;Z:2

Fig. 8:
PKD is very convenient because oi its high abrasiva resistance, lhe low lnfluence oi lhe tool
sliding friction coefficient and lhe good thermal conduction. With increasing edge geometry on the
10 20 JO Gim 50 cutting forces (lighl
grain size the tendency for edge break-outs rises.
effective cutting ongle - metal machinlng)

G-AI Si12 (Cu) .t.TiA\6V4

L::,-F-4::""1C:,,i; aildown mijirç •• 20'
l, O' -' 1 11 11· , .. KlO
IF'1=--k'71-"""'b,-- :::...+-+-l dry a,I v,,tOOOmlmin
l--1""-6""3 E:c:+--+--!-+-+-l
v1= 9m/mm
v,'2500 m/mrn
2
1
., '\; JJ' l Ll 1 U: lt1 11110.IIMI
1 ,< µj
•Greek Ascoloy
H "'l--t---'f-+-+--1-+-+-l :•:};:; ;/

1:
mm
1, ,,,= F;; \ P40/50
ttr'-l--+---+-+--l--+--i-+--+--i C=l 1Zº
T: 15° J.=7 .-imillirç v,,JOOm/1110
,5 +--+--+--i-+--+--i >. : Oº dry a,t - f=
1 0.1mm
I
5 a,,smm _
j O O:- -:ijjt:-- -,lllt:-- .,,120t:-- -=li0=- m--=-200r • 0.02 mm Fig.9: 0.1
,,,,1.5:"" 1 • lnconel 718
cutting length 11 - lnfluence oi lhe tool edge º-li ·8 -4 0 4 8 li 16 20 2' 6n:rl 31
KlO
geometry on tool IHe v,,m mt""'
Fig. 6: Wear p,operties oi different cutting materiais while (machining special steels droft a,gle a- f1:QOS mm
high speed machining lighl metal alloys and alloys) effective cutting orgle -- ..
3.3 Design of Tools
When machining copper alloys there are no uniform cutting qualities By today's standards optimized cutting speeds for wear, surface quality,
evident because of the differences in chip formatíon caused by their unlike low cutting forces and temperaturas are max. 6000 m/min.
structure and thermal conduction. The centrifugai forces strain the tool's basic paris, the fix1ure of lhe cutting
For copper materiais one may use the hard metal K10 as well as PKD /28/. inseri and the cutting edge material. When fast-rotating tools break, high
Mixed ceramics and sílicon nitride are not suitable because of their high mechanical energJes are released which can damage machine parts or
adhesive tendency. High-speed steel tools do not achieve a sufficient tool even injure the operator. Unforlunately, to date, there are no standards or
life travei. Especially when processing difficult-to-machine materiais and rules for testing and constructing such toeis. Therefore at the Technical
alloys with sticking tendencies, PKD demonstrates its superiority not only Uníversity of Darmstadt, at the lnstitute oi Production Engineering and
by a better wear resistance but also by higher surface qualities and lower Machine Tools (PTW), a special joint research project has been
cutting forces /15/. established in arder to work out design and testing directives and
High tool wear when machining flber relnforced plastlcs is caused by recommend standards.
damaged surfaces and abrasion. Only cutting egde chamfers are seen on Finita element calculations show that form and depth oi chip space
aramide fiber reinforced composites. grooves deeply influence the notch tension. There are ex1reme stresses
Carbide K10 can be used with good results /98/. especially on the chip space ground and in lhe clamping zone oi the
cutting inserts (fig. 10) /17/.
Flank wear caused by the sharp edges of the fibers occurs when
machining carbon- and glass flber relnforced plastlcs. When cutting

Fig. 7:
wear properties oi different
cutting materiais while high
speed machining fiber
reinforced plastics Fig. 1O: Notch chip building as a function oi the toors geometry

639
 t 1101!11 1
t t--+--+--
I oumnun/cqiper
-;;f,;H'! --------------- 1 >.!!!..1---1---+-- ll cosi iron/sleel
CZl crnsh • Y A! .'11111
>- lll:fibre reinfarced
e
1 u BOIIIJOH'Fi-L-----'----vl--V\-- llill l"'JJ'l"CY ,_,·6000 m/m1n
1 oo crill:ol solely loci>r 1·11
>--+--+--
]) 301----+--+--
plastics

- cc 60000W :t-.,,.,-------U--vl--l t rosalety

10000
Fig. 11: Safety comparison oi available toais
ln most cases currently available toais are not safe enough (fig. 11).
Based on lhe experience gained by completed research one can derive
the following basic designing directives for fast-rotating toais:
1. Use ductile materiais
2. Minimize the notch effect (dependent on the necessary chip space).
3. Minimize the notch effect (dependent on the cutting edge design).
4. Provide for form-fit connections
5. Maintain low massas for all tool components
6. Arrange center oi mass on small radii
3.4. Interface Splndle • Tool
The results of high speed cutting depend decisively on the interface
spindle - toai and on the clamping system which must operate under
especially difficult conditions. The interface is situated directly in the force
flow between workpiece and machine. The optimum design must
guarantee the rapid automatic toai change and high performance functions
as well as highest changing and repeating accuracy. ln addition to lhe
general requirements on cutting, (for example the transmission oi Iorque
and cutting forces), there are additional demands on hsc-machining: Small
balance errar, high concentricity, high run-out tolerance and position
accuracy, reduced centrifugai force influenced by small radial dimensions
and massas.
Because oi the high speeds there are centrifugai effects both on the
spindle cone and the toai taper (fig. 12). Here lhe spindle expands more
than the toai so that the toai axially displaces itself by the clamping force.
By these deforrnations the contact surfaces are diminished and therefore
the frictionally engaged transmission oi torque occurs. Furthermore lhe
centering oi the toai is no longer guaranteed. Alter stopping the spindle
rotation the elastic deformations diminish, a press fit develops which is
difficult to release. The axial offset can be prevented by implementing
facing stops /18, 52, TT/.
Straight shank toais can be clamped by a chuck or a hydraulic expansion
chuck. Their functional properties are no longer sufficient by modem
standards /65/.
radial expCJ1dlng J -,
------------- 1
Fig. 14:
Optimum technology
application ranges for
high speed cuttlng
4.1 Machine Base
ln arder to obtain good dynamic performance the bases should be made
out oi polymer concreta. The advantages specific to material forming with
appropriate materiais leads to improvements and cost reduction /8, 76/.
4.2 Highfrequency Malnsplndles
The most important component is the mainspindle, designed as a
motorspindle with an integrated motor. The frequency regulated motor is
always situated between the bearings. A short and rigid construction
results in higher criticai frequencies. Special roller bearings are used
primarily (fig. 15). Active magnetic bearings /1, 56/ and air bearings can
also be utilized in respect to maximum motor performances resp.
maximum moments are achieved by the rotor measurements. Toe largest
diameter is limited by the allowed circumferential speed, i.e. by lhe
consistency oi the used materiais. For continuous operations a speed oi
approx. 125 m/s is used, for operation oi short duration, 150 m/s is
possible /13, 16, 93/.
Fig. 15:
Roller beared motor spindle
Fig. 16 shows the present performance range oi motorspindles supported
by roller bearings. Here the choice oi the lubrication is important (78, 79/.
With minimum oil lubrication lhe heat oi the bearings and the rotor cannot
sufficiently be removed allowing only lhe thermal conduction from lhe
bearings to the housing. Oil cooling lubrication not only coais the bearings
but also removes the heat which flows from the rotorto the bearings.
The stator is cooled by oil or water in arder to limit lhe temperatures in lhe
interior oi the motor and therefore the bearing temperatures.

Fig.16:
- oil-cooling lubncation Performance range oi
.....•. minimum oil lutricalim present hsc-motor spindle
o.. 111----i--c;l'H--------------- i units
clomping force ---·-----·
EJ clea-once bel,..n ilol shlll ond spide """
l 10t---\'t7":*-t---;---;-- ;
llf--- f---f---j -- j
l01t -- f½r

Fig. 12: Chuek deformations intluenced by centrifugai forces

frl:l]Uency n
By using the new hollow taper shanks for automatic toai exchange ln most cases motorspindle bearings are equipped with specially designed
(DIN 69893, form A; German Industrial Standard) the radial and axial high accuracy angular ball bearings. The maximum frequency depends on
clamping forces are divided between severa! clamping elements whereby the arrangement, size and lubrication oi the bearings. ln already existing
these forces act upon the internai parts oi the toai (fig. 13). motorspindle components the following parameters (n•dm) are realized /22,
23, 95, 53/:
6
continuous grease lubrication: 1.3• 10
6
minimum oil lubrication: 1.8(2) • 10
oil cooling lubrication: 2.5• 10 6

Axial and radial rigidity in roller bearing motorspindles varies depending on

Fig.13:
Hotlow tapar shanks for the speed (fig. 17). Therefore the initial tension oi lhe bearing must be
automatic tool exchange regulated according to the speed.
(DIN 69893, form A)
Fig. 17:
Rigidlties oi present
m hsc-motor spindle unils
The arrangement oi the clamping mechanisms (similar to the infinitely
variable change-speed gear) results in secure system locking and a
o
fourfold strengthening oi force. 00
.. V/2
4. Machine Tools for Hlgh Speed Cuttlng
00
(.( D>-
The realization of the hsc-techology can only be realized with
unconventional new solutions for the basic machine conception and all -- llfllr r--,.._
::---...
Llllll
decisiva components.
ln regard to lhe optimized cutting speeds and feed-rates, it can be said that o 10 10 lO 60 7 IIÂTlflXKH/ !iO
there is no hsc-machine for universal application (fig. 14) (72/. frequency n -

640
4.3 Carriages
Ali moving machine parts must be produced in lightweight construction by / Ck 45
using new materiais such as aiuminum titanium or fiber reinforced plastics. / culdówn mdling
ln contrast to present constructions one can achieve larga mass IJH------\--t--+----+--+--+----j dry cul
reductions (up to 40%). 11 ,QJlmm
0 o,,1.5mm
> o.a Cermel a,, 5nm
.!!?
Sii N
0.4f--,- :-"' =61---9- -:-:---:-'.411
,Qlónwnl d • 40mm
a, 16° Fig.19:
lnfluence oi the
TiN o.JI PZ0/30 ,t o• cuttlng material and
'-' (PVO) lhe input paramelers
,ro ln! 12(1) mArfl 211D onlhe economic
culling speed v, eflieiency

1 cutdown m1tllng
t Q75
0P20/25 óry cul
Vc= 800m/min
ICBN
1\;! 0.5
1,, 0,16mm
o,, 1,Smm
a,1 Srrm
Fig.20: d= 40mm
à;
Economic efliciency e,. tt:16°
Fig. 18: Consequences oi the lightWeight construction oi moving machine componenls comparison between .!!? 0,25 l = 0°
hard metal and CBN l!! rlCBK\•O.llmm•ZOº
'-'
By reducing the linear and rotating massas a circulatory system is opened while hsc-milling diflerenf
sleels Ck45 42 rMo4 lXJCr6
that results in the reduction oi inertia oi mass in adjoiníng machíne
components /69/ (fig. 18).
Reduction oi weight can be achieved by: Nowadays one can prove tool- and material specific time reductlons oi
Selection oi appropriate construction material over 50%1721. li only the smoothing processes are considered, reduction
Application-specilic light weight construction increase to 80 - 90 %. /58/
Optimize the geometric dimensioning by using finite-element program
lnvestigation oi the effects on adjoining machine components 6. Application of HSC-Machines
Today many machine toais already have as a standard feature higher
4.4 Guideways spindle speeds oi 8000 to 12000 rpm and higher feed ra1es oi 20 to 25
Due to high inleed speeds only antilriction guideways with rolier or bali m/min. Therefore in most cases they can be used for the hsc-machining oi
bearings are used in modem machines. steel, cast iron or special alloys, when equipped with the appropriate
4.5 Feed Drives security devices.
By using multiple thread rolier drives instead oi bali-screws the moments oi High speed machines for machining light metais or piastics normaliy are
inertia as weli as space requirements can be reduced and lhe inleed per equipped with main spindles with speeds ootween 25000 and 50000 rpm,
spindle rotation can be increased near1y threefold. Therelore one can in special cases up to 100 000 rpm.
achieve high'leed rates (over 100 m/min). The range oi hsc-machine application is primarily oriented to the
The leed drives must demónstrate specialiy good dynamic characteristics, advantages oi high-speed machining (fig. 21).
i.e. contrai loops with smalier time constants and motors which can
generate high moments for short periods oi time. technologlcal advantage appllcatlon lleld appllcatlon examplu

4.6 CNC-Control Systerns big cutting volume / time llght metal alloys aircraft and aerospace production
Because oi the high leed rates there are extreme demands placed on the ateei and cast iron tool and dia mould manufacturing
internai processing speeds oi lhe CNC-controls. Present standard contrai
systems are too slow for the required leed rates because the time for the precision machlning optical induatry, fine macha.nicai
high surface quality
parts
CNC-sentence processing is higher than the prorated time oi lhe cutting
special workpiecas spiral compresaors
path supporting points. Furthermore the programs can become very
voluminous because oi the amount oi supporting points. li the data low cuning forces processing of thin-walled aircratt and aerospace industry,
transmission is slower than the sentence processing a standstill oi the workpieces automotlve industry, household
equipments
machine will result. Therelore larga program storage capacity in the
megabyle-range is required, as is offered in the newest CNC-systems. high frequencies of excitaUon
no machining in criticai precision machanics and
frequencies optical industry
The solution lies in the use oi shorter system times, the look-ahead
function and spline-interpolation /14, 22/. Spline interpolation enables a cutting heat transpor! by lhe machining of wcrkpieces wich precision mechanics
magnesium aUoys
reduction oi nc-sentences because severai linear sentences are combined chips criticai heat influence

in one ;;pline-sentence. Splínes with tangential transitions between lhe Fig. 21: Appllcalion ranges oi high speed cutting
sentences reduce the required accelerations and enable smoother
movements as opposed to the sudden direction changes oi the linear Figures 22-24 illustrate some examples oi hsc-machines.
interpolation.
Based on normal applications oi 3-axes free form surface machining with Fig. 22:
spherical head cutters, it is clear that there is a demand for 5-axes- 5-axes high speed milling machine
machining in order to prevent the cutting speed O ln lhe cutter center. On for 1001 and die mould manufacturing
a 5-axes machine toei lhe cutter can be exactly positioned orthogonaliy to (MAHOAG)
lhe surface. Also for thls reason one needs faster contrel systems.

4.7 Chip Remova! and Coolant System

The high chip production per time unit sets extreme demands on the chip
remova! systems. Therelore it is recommended to clamp the workpiece
vertically. New high pressure spray cooling systems assist in chip removal.

4.8 Securlty Devices

The high chip production, catapulting chips and the spraying oi coolant
requires an incapsulation oi the working space. Salety precautions for toei
breakage have absoluta priority, The cabin wali must be able to absorb the
energy oi a catapulting part without breaking /17, 26/. Besides these
passive security arrangements there must be active controlling systems,
(so-calied in-process-control-systems), which guarantee perfect operation
because the operator can no longer interfere with high-speed processes
/94/. .

5. Efficiency
Compared to conventional machine toeis the economical application oi hsc
machines is deeply inlluenced by the choice oi the right cutting technology,
the optimum cutting speeds, leeds and the optimized tool. This means for
every material to be cut there is a specific, relatively small range of
Fig.23:
operation which depends on the input parameters oi the machine tool High speed milling machine for
(feed rate, speeds, cutting depth), tool geometry and -material (fig. 19/20). big aeroplane parts composed oi
aluminum alloys (HAMÜL)

641
 Fig. 24:
5-axes high speed
milling machine for
worl<pieces CO"l)OSed
oi liber reinforced
plastics and lightmetals
(PTW)
7. Prevlew
Hsc-cutting can be used for the entire process when machining light
metais, non-ferrous metais and plastics; while for machining steel, cast
iron and difficult-to-machine alloys hsc-cutting is suitable for lhe final
cutting process. ln many cases the decisiva advantage in creating high
quality surfaces with hsc-cutting allows the shortening oi some subsequent
final processes, such as grinding; or based on the better surface, time for
final processing can be significantly reduced.
This is the case especially in toei and die-mould manufacturing.
The increase oi the technologically optimized cutting speeds and feed
rates is mainly a question oi the velocity oi CNC-control systems and the
feed drive dynamics. ln order to reduce the linear and rotating massas with
equal rigidity for ali moving parts, the light-weight construction techology
must be consequently promoted. Machine security devices are still
insufficient. Furtherrnore, there are no design and contrai directives for fast
rotating toeis. Proposals for standardization and security design will be
available within the next 2 years based on PTW research. Special
applications, for instance printed circuit drilling with toei diameters less
than 0.5 mm, require main spindles with speeds between 300,000 and
400,000 rpm.
User demands for workpieces manufactured with high precision
necessitates lhe rapid development oi high-accuracy hsc-machine toeis to
meet futura industry requirements.
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