In the past 10 to 15 years HSM was focused on the mold and die industry that uses pre-hardened materials and hardened tool steels—such as P-20, H-13, S-7 and D-2, which range in hardness from 28-62 HRC. The traditional method of finish machining hardened materials was EDM. In applications where HSM can replace the EDM process there will be considerable cost and cycle time reductions.
To be successful with HSM the following components need to be integrated; if one of these is incorrectly applied then your machining application will suffer.
This is the most significant component for HSM, and should be designed specifically for HSM. The construction of the base, as well as the individual components—drive train, spindle and CNC—must be capable of handling the demands of HSM, especially in the case of hard milling.
It is much more than just looking at the maximum spindle rpm and feedrates. You must consider the size and mix of work to be machined. Know what you are planning to machine and evaluate accordingly. Are you going to be machining 2-D or 3-D surfaces on components or are materials to be machined, soft or hardened? These are just two examples.
用最高主轴RPM购买机器：40K带1,000 IPM进料。听起来很棒，对吗？让我们进一步进一步：所有部分都是非常复杂和小的，您拥有一些最好的HSM切割工具（在直径上1.0毫米。/ 2-长笛），专为60k转/分，芯片负载为0.003“。现在，您受到40k主轴的限制，因此您必须以40k的降低的RPM运行刀具。计算进料（40k x 2x.003“），您有240个IPM进料。现在我们拥有40k rpm和240个IPM，所以我们真的在移动！
For instance, if a tool is to be run at 9K rpm and used in a roughing application it very well may not need to be balanced. On the other hand, toolholders that will be used for finishing operations at speeds above 8K rpm may benefit from balancing. It all depends upon your requirements.
This is one area where companies try to cut corners because of the cost associated per piece, but there are more variables to consider—performance and better finishes, along with how long the tool will perform well in the cut. In some cases, you can throw commodity-type tools at an application, but you will have shorter and less consistent tool life, resulting in more downtime changing tools, etc. You need to know what is expected of the cutting tool—surface finish, material hardness and tool life requirements—so you can run lights out, unattended.
There are still many CAD/CAM systems that do not have the capabilities to create toolpaths for HSM or hard milling routines easily. To be able to evaluate a system, you must understand what types of routines are required for HSM to attain the best results. Using experts in the field will reduce your learning curve considerably.