High Feed Milling

September 21, 2017

High Feed Milling Definition

 

 High feed milling is a roughing method developed to achieve higher material removal rates increasing productivity.

 

 The process combines a shallow depth of cut with a small approach angle to ensure that the cutting forces are directed towards the machine spindle in the axial direction, which results in greater tool stability, allowing for increased feed rates, sometimes up to 10 times the normal rate. 

 

It is always a question of thickness…

 

 

When the approach angle = 90°, the maximum chip thickness (hex) is 100% of fz.

Fz = 0.25mm/tooth / Hex = 0.25mm

 

 

 

 

 

When the approach angle = 45°, the maximum chip thickness (hex) is 70% of fz.

Fz = 0.25mm/tooth / Hex = 0.175mm

 

 

 

 

 

 

 

When the approach angle = 10°, the maximum chip thickness (hex) is 17.3% of fz.

Fz = 0.25mm/tooth / Hex = 0.043mm

 

 

 

 

 

We need to resize

the chip thickness… 

 


 

By increasing the feed rate, the chip thickness is resized to original. 

 
Fz = 1.45mm/tooth 


Maximum Chip Thickness
Hex = 0.25mm

 

 

Resultant Forces and Effects 

 

Generates mostly radial forces, in feed direction.

 

- It causes vibration if there is long overhang.

 

- Only option for Shoulder Milling.
 

 

 

 

 

 

 

The predominant axial cutting force is directed towards the spindle and stabilizes the cut. 

 

This is favorable for long overhang, because it reduces vibration tendency

 

 

 

 

 

 

Initially used on the Mold and Die industry, this process has become popular also in other industries. With a small approach angle, the amount of removed material is increased by its spread over the cutting edge.

 

It boosts the performance on the operations:              Facing

                                                                       Ramping

                                                                       Helical Milling

                                                                       Pocketing

                                                                       Plunging

                                                                       Copying

                                                                       Sloting

 

High Feed Milling Lamina

 

Solid End Mills

 

 

Diameter range 
3mm – 12mm

 

Max D.O.C.
0.025 X Diam.
 
Max W.O.C.
0.5 X Diam.
 

 

 

 

Indexable Inserts

 

 

SDK… 0904-HF…

 

Milling Cutters : LT 902

 

Diameter range 
25mm – 52mm

 

Max D.O.C.
1.5 mm

 

SDK… 1205-HF…

 

Milling Cutters : LT 903

 

Diameter range 

32mm – 80mm

 

Max D.O.C.
2.0 mm

 

 

 MULTI-FUNCTION MILLING LINE

 

 1 milling body for 2 milling applications and limitless machining :

 

       Shoulder 90° insert                                        High Feed Inserts
APKT 060204 PDTR LT 3000              APKT 0602-HF LT 3000     APKW 0602-HF LT 3000

 

APKT… 0602-HF…

 

Milling Cutters : LT 752 …

 

Diameter range 
10mm , 12mm and 16mm
(coming soon D20mm and D25mm)

 

Max d.o.c. = 0.5 mm

 

 

Tests

 

 

Important Remarks

 

For circular movements like helical milling, the table feed must be slower and can be compensated by the factor like shown.

For Ramping Down Engagements during Pocket Milling is very important to respect the recommended maximum Ramp Angle, in case of using higher values, the cutting edge can be overloaded and the insert will break.

 

 

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