High Feed Milling
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
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.
Milling Cutters : LT 902
Diameter range 25mm – 52mm
Max D.O.C. 1.5 mm
Milling Cutters : LT 903
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
Milling Cutters : LT 752 …
Diameter range 10mm , 12mm and 16mm (coming soon D20mm and D25mm)
Max d.o.c. = 0.5 mm
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.