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Title : Methods And Analysis of High Speed Machining (HSM)
Author: Raghavendra
Department Of Mechanical Engineering
Author: VISVESVARAYA TECHNOLOGICAL UNIVERSITY
ISSN :
Volume: 01 Issue: 01
Publication Year: June 2026
ABSTRACT
High Speed Machining (HSM) has emerged as an advanced manufacturing technology that significantly improves productivity, accuracy, and surface quality while reducing machining time and overall production costs. In modern HSM applications, various machine tool configurations are employed, with 3-axis Vertical Machining Centers (VMCs) and Horizontal Machining Centers (HMCs) being the most commonly used. Although VMCs present certain limitations in chip evacuation, their lower cost and wider availability make them the preferred choice in industry. Advanced 4-axis and 5-axis CNC machining centers further enhance machining capabilities by enabling tool tilting, improved cutting conditions, and complete roughing, semi-finishing, and finishing operations in a single setup. HSM has been successfully applied to a broad range of metallic and non-metallic materials, including hardened steels exceeding 50 HRC hardness. In die and mould manufacturing, machining and polishing operations account for a major portion of production lead time and costs, making process optimization essential. Typical HSM systems require high spindle speeds up to 40,000 rpm, spindle power above 22 kW, programmable feed rates of 40–60 m/min, rapid traverse speeds up to 90 m/min, high thermal stability, advanced CNC look-ahead functions, and efficient coolant delivery systems. By integrating these capabilities, HSM enables superior surface finish, reduced manual finishing requirements, and enhanced manufacturing efficiency, making it a key technology for modern precision engineering and die-mould production industries.
1.0 INTRODUCTION TO HIGH SPEED MACHINING
1.1 Introduction to HSM:
Over the past 60 years, high speed machining (HSM) has been applied to a wide range of metallic and non-metallic work piece materials including the production of components with specific topography requirements and machining of materials with hardness of 50 HRC and above. With most steel components hardened to approximately 32-42 HRC, machining operations currently include:
• Rough machining and semi-finishing of the material.
• Heat treatment to achieve the final required hardness.
• Machining of electrodes and electrical discharge machining of specific parts of the dies or moulds.
• Finishing and super finishing of surfaces.
In leading industrial countries, in die and mould manufacturing, a significant portion of the lead-time is spent for machining and polishing operations .Therefore the machining and polishing portion of dies and moulds takes approximately two third of total manufacturing costs. If the quality level after machining is poor and if cannot meet the requirements there will be varying need of manual finishing work [1].
Machining with high speeds (HSM) is one of the modern technologies, which in comparison with conventional cutting enables to increase efficiency, accuracy and quality of work pieces and at the same time to decrease costs and machining time.
1.2 What is HSM?
The first definition of HSM was proposed by Carl Salomon in 1931. He assumed that “At a certain cutting speed which is 5-10 times higher than in conventional machining, the chip removal temperature at the cutting edge will start to decrease”.
The figure below illustrates his definition. There is a relative decrease of the temperature at the cutting edge that starts at certain cutting speeds for different materials.
• High cutting speed machining (Vc).
• High rotational speed machining (n).
• High feed machining (Vf).
• High speed and feed machining.
• High productive machining.
Finally, “HSM is a powerful machining method that combines high feed rates with high spindle speeds, specific tools and specific tool motion”.
Figure below shows the generally accepted cutting speeds in high speed machining of various materials.
1.3 History:
High-speed machining (HSM) has recently achieved wide acceptance in the rotorcraft and fixed-wing aerospace industries, especially in the production of thin-walled monolithic aluminum airframe parts. This technology offers several advantages for reducing costs and improving productivity, and allows aluminum airframes to be designed and manufactured monolithically, i.e., in a single long uniform piece that replaces several smaller airframe parts: The current technology process produces the following advantages for thin-walled monolithic aluminum parts:
• Fewer parts and fasteners are required.
• Thinner walls and webs with less distortion can be made.
• Reduction occurs in final assembly labor, because parts fit better.
• Parts are machined two to five times faster.
• Forgings can be replaced by aluminum bar stock, which reduces cost and lead time.
In addition to providing extremely high metal removal rates (MRR), a key attribute of HSM over conventional machining is that in many cases the new process yields improved dimensional accuracy, as most of the heat generated is removed with the chips and hence does not build up in the work-piece to generate distortion [2].
This improvement in machining capability was due primarily to the use of new types of machine centers that could machine at higher feed rates and higher spindle speeds. Not only were these machine centers faster; they could also machine more accurately and produce thinner aluminum walls due to improved system stiffness, better heat removal,
more accurate controls, and carbide cutting tools. As Fig. 3 illustrates, the 1970’s conventional machine centers that operated in the 2,000–5,000 rpm range have been shown to be less efficient in machining features when compared to the high speed spindle technology of the 1990’s when applied to aluminum parts.
1.4 Definition of HSM:
It would be beneficial to provide several definitions of HSM before going further. HSM is sometimes defined as a combination of tool size and speed that yields 1.0 to 1.5 million Dn (diameter of the main bearing in millimeters times the speed [rpm] of the spindle)[3]. Another more general definition is that HSM parameters begin when a 1/2-inch end mill turns at more than 8,000 rpm and its feed rate is 250 in/min or higher. The definition preferred by the Machine Tool Research Center of the University of Florida at Gainesville, where this HSM effort of this project was conducted, is as follows:
“High speed machining occurs when the tooth passing frequency approaches the dominant natural frequency of the system.” height. The specimen was modeled proportionally to the production part in the sensitive web area, where distortion.
2.0 HSM SYSTEM Methodology
2.1 Machine tools:
In HSM, various configurations of machine tools are being used. However 3-axis horizontal and vertical milling centers (HMC and VMC) are most configurations. Al though vertical machining centers have disadvantages concerning chip removal, they are the less expensive choice and therefore, are presently more widely used than horizontal machining centers. CNC 4-axis milling offers the option of tilting the milling cutter to improve the cutting conditions. Five axis machines with interchangeable spindle units allow to rough, semi finish and finish with a single set up. It also allows the machining of work piece having large diameter.
Below are some typical demands on the machine tool and the data transfer to HSM (ISO/BT40 or comparable size, 3-axis):
• Spindle speed range <=40000 rpm.
• Spindle power >22 KW.
• Programmable feed rate 40-60 m/min.
• Rapid travels <90 m/min.
• Block processing speed 1-20 ms.
• High thermal stability and rigidity in spindle.
• Air blast/coolant through spindle.
• Advanced look ahead function in the CNC.
2.2 Cutting tools:
Among the cutting tools used for machining castings and alloy steels carbide is the most common tool material. Carbide tools have a high degree of toughness but poor hardness compared to advanced materials such as cubic boron nitrite (CBN) and ceramics. In order to improve the hardness and surface conditions carbide tools are coated with hard coatings such as titanium nitride (TiN), Titanium carbonitride (TiCN) and titanium aluminum nitride (TiALN) and recently with double/soft coatings such as MOVIC[4]. Other cutting tool materials are Ceramics (AlO, SiN), cermets and poly crystalline diamond (PCD).
In general tools ranging from 0.5 to 1.5 inches in diameter carbide insert tools with TiCN coatings are significant for the materials with less than 42 HRC, while titanium aluminum nitride coatings are used for materials with 42 HRC and over. However depending on application, materials and coatings for the best performance vary. High speed cutting application for such tool materials and coatings can be classified as:
• CBN and SiN fore cast iron.
• TiN and TiCN coated carbide for alloy steel up to 42 HRC.
• TiAlN and AlTiN coated carbide for alloy steels having hardness 42 HRC and over.
For special applications especially for hard turning (HRC 60-65) PCBN inserts with appropriate edge preparation are also successfully used.
2.3 Need of coated tools:
Hard coating applied to cutting tools can significantly alter the properties of the tools. Low coefficients of frictions and low tendency to adhesion of the coating to the work piece material will result in less heat generation during the cutting operations [5]. The low thermal conductivities of the coating will generate a thermal barrier on the tool surface. Less heat will be transferred to the tool and thus a major part of the generated heat will be transported away from the cutting areas with the chips. In addition high thermal stability, hot hardness and oxidation resistance resistances will reduce the wear of the tool.
2.4 Some specific demands on cutting tools made of solid carbide:
• High precision grinding giving run out lower than 3 microns.
• As short out stick and overhang as possible, maximum stiff and thick core for lowest possible deflection.
• Short edge and contact length for lowest possible vibration risk, low cutting forces and deflection.
• Oversized and tapered shanks, especially important on small diameters.
• Micro grain substrate, TiAlN-coating for higher wear resistance/hot hardness.
• Holes for air blast or coolant.
• Adapted, strong micro geometry for HSM of hardened steel.
• Symmetrical tools, preferably balanced by design.
2.5 Specific demands on cutters with indexable inserts:
• Balanced by design.
• High precision regarding run-out, both on tip seats and on inserts, maximum 10 microns totally.
• Adapted grades and geometries for HSM in hardened steel.
• Good clearance on cutter bodies to avoid rubbing when tool deflection disappears.
• Holes for air blast or coolant.
• Marking of maximum allowed rpm directly on cutter bodies. Specific demands on cutting tools will be further discussed in coming articles.
2.6 HSM Enablers:
An HSM tool path is one that reaches and maintains very high spindle speeds and feed rates, with a trajectory that is smooth and rounded throughout, no matter what the topology of the part. Cimatron utilizes four Enablers that can turn any traditional tool path into a fully optimized HSM tool path [6].
There are Four HSM Enablers they are:
• All Rounds.
• Clean Between Passes.
• Tangential Approach/Retract.
• Trochoidal Machining.
2.6.1 All Rounds:
When cutting at high feed rates, there can be no sharp corners in any of the passes, as this will cause machine jerks which will leave marks on the part itself and damage the tool and the machine. During calculation of the tool path, the system automatically rounds all passes where necessary.
2.6.2 Clean Between Passes:
This is to ensure that a constant sidestep and uniform scallops are maintained no matter what the complexity of the geometry. The system automatically adds extra passes where there are variations in sidestep.
2.6.3 Tangential Approach/Retract:
When machining at high speeds, the approach to the part and the retract must be rounded and tangential to guarantee a smooth engagement.
2.6.4 Trochoidal Machining:
This removes large ridges resulting from rounding sharp internal corners. While trochoidal roughing is a standard part of HSM roughing, trochoidal finishing is often problematic because it can cause witness marks. Cimatron Zero Overlap Trochoidal cutting uses an advanced algorithm to bypass this problem and produce a truly smooth surface finish.
HSM Enablers will be demonstrated on the section. This tool path has not been optimized for HSM and, as a result, has sharp corners.
The tool path above is using the “all rounds” enabler only, this causes significant variations in side step. The above tool path includes All Rounds, Clean between Passes (white) and Trochoidal Machining (Yellow).
2.7 HSM Machining Strategies:
In any situation, achieving the best possible surface quality means keeping scallop size as small as possible, achieving a small radial cutting width (ae) and starting the finish operation with a uniform remaining stock. Surface quality can also be improved by having as few tool lifts as possible, few tool changes and a minimum amount of machine vibrations. Additionally and very importantly, the finish strategy has to be adapted to the surface topology. All these factors are as true for HSM finishing as they are for traditional finishing[7].
In order to provide the flexibility to perform High Speed Milling effectively on any topology, Cimatron takes four main types of finishing strategies and optimizes them to work at very high speeds, by incorporating the HSM Enablers.
In addition, Cimarron offers further flexibility by providing a powerful Remachine capability which is designed for finishing of corners with small radiuses. The four types of strategies, as well as Remachine, can be further optimized to the topology by getting the system to match the right strategy to the right geometry or by using 5-Axis technology. All of these additional methods work effectively and safely when performing HSM[8].
We will discuss HSM finishing strategies in three parts by looking first at the four types of finish strategies, then at Remachine and lastly focusing on Strategy Optimization.
2.8 Finish Strategies for HSM:
Finish Strategies for HSM are four different types of finishing operations. These ‘types’ are in essence a full category from which many different strategies can be derived depending on the parameters.
Types of Finish Strategies for HSM:
• Parallel strategy.
• Z-layers strategy.
• Spiral strategy.
• Morphing strategy.
2.8.1 Parallel strategy:
The first type of strategy is a Parallel strategy in which the tool path moves along straight lines with a constant distance between passes. This strategy is mostly effective for geometries that are shallow or flat across the path direction; because a slope across the passes would result in an uneven sidestep as measured on the surface of the part [9].
2.8.2 Z-layers strategy:
The second type of strategy is a Z-layers strategy which divides the geometry along the Z axis producing a tool path that cuts according to the geometry, at a certain height. This strategy is particularly useful for the machining of steep walls.
2.8.3 Spiral strategy:
The third type of strategy is a Spiral strategy. In this strategy there is a constant sidestep between the passes which are enclosed by one or more contours. This means that the strategy can be applied to a wide range of geometries and shapes, producing a smooth surface quality.
2.8.4 Morphing Strategy:
The fourth type of strategy is a Morphing strategy. This strategy ensures a constant number of passes between one contour and another. This means that the passes are very responsive to the geometry of the contours, and flow with the natural geometry of the surfaces; it can however result in major variations in sidestep, depending on geometry.
2.9 Remachine:
Remachine is a highly optimized method of automatically removing material from a part that was left over by a previous cutter. Remachine includes reroughing, to ensure uniform stock width for the finish passes, and finishing, to achieve an optimal surface quality in just one operation [10]. Because Remachine can optimize several of the different types of finish operations mentioned above, it is extremely flexible. An example of this flexibility is Remachine All Along, which creates a tool path that works along the natural flow of the material that has to be removed. The Dilute option allows the user to skip passes in narrow areas where they are not necessary, saving machining time. The user can turn this option off (No-Dilute) to produce a super finish surface quality with no tool lifts.
2.10. Strategy Optimization:
• Vertical/Horizontal Machining.
• Multi-cutter Machining.
• 5-Axis Machining.
Vertical/Horizontal, Multi-cutter and 5-Axis machining further enhance the strategies Mentioned above, allowing these strategies to be used in the most efficient way possible.
2.10.1 Vertical/Horizontal Machining:
Automatically combines two different strategies, by applying one machining strategy to steep areas and another strategy to areas with a gentle incline. The user simply specifies the boundary slope angle and the two strategies that should be used.
2.10.2 Multi-cutter Machining:
Chooses the optimal cutter in a situation where the geometry requires the use of a very long cutter during some of, but not all of, the finish operation. Multi-cutter will consider two or more similar cutters with different lengths and holders, using the shorter, more efficient cutters wherever possible, and using longer cutters only where they are absolutely necessary [11]. Machining conditions, such as feed rate, are controlled per individual tool, to accommodate for the different tool lengths.
2.10.3 5-Axis Positioning Machining:
5-Axis Positioning can significantly increase productivity and surface quality by cutting the part from the optimal angle using shorter tools. In many situations this may mean that an area that would have needed Vertical/Horizontal or Multi-cutter optimization can be completed using one simple strategy.
2.10.4 5-Axis Tilting Machining:
5-Axis Tilting is an option that uses simultaneous 5-Axis milling to allow the tool to reach all required areas while avoiding collisions between the part and the shank or holder. Thus short robust tools can be used, with no or fewer tool lifts throughout the part. While simultaneous milling of freeform parts can be very complicated and time consuming, Cimatron Tilting is very simple to program; there is no need to define guiding contours.
RECOMMENDED PARAMETERS FOR HSM
3.0 Parameters of HSM:
Some recommended parameters for HSM are:
• True cutting speed.
• Material removal rate.
• Surface finish.
• Tool cost and machining cost.
• Cutting fluid in HSM.
3.0.1 True cutting speed:
As cutting speed is dependent on both spindle speed and diameter of tools, HSM should be defined as “true cutting speed” above a certain level. The linear dependence between the cutting speed and the feed rate result in “high feeds with high speeds”.
Where ap = axial distance from the tool tip to the reference point n = spindle speed
De = effective diameter
3.0.2 Material removal rate:
The material removal rate, Q is consequently and considerably smaller than in conventional machining with the exception when machining in aluminum other non ferrous materials and in finishing and super finishing operations in all types of materials.
Where Vf = feed speed
ae = step over distance
3.0.3 Surface finish:
Like in conventional machining the surface finish in HSM is determined by conditions like the cutting tool geometry, coating of the cutting tool, wear status of the cutting tool, lubrication, cutting strategy determined on the CAM system, cutting tool extension, work piece material etc. Assuming all these parameters are controlled, the surface finish to be expected may be calculated through the following approach.
Where Rth = theoretical surface roughness D = diameter of cutting tool
ae = step over distance
Since the maximum cutter diameter is often limited by the part geometry, Rth only can be minimized by decreasing the step over distance.
3.0.4 Tool cost and machining cost:
When introducing HSM, cost of cutting tools will increase significantly. The benefit of HSM is given by a reduction of processing time and cost, better surface finish, reduction of manual finishing work, better accuracy etc. For this reason cutting tool cost should only be seen as an integral part of the overall cost accounting [12]. Machining cost will be less than the conventional machining process due to elimination of process steps, reduction of process time etc.
3.0.5 Cutting fluid in HSM:
In conventional machining, when there is much time for heat propagation, it can sometimes be necessary to use coolant to prevent excessive heat from being conducted into; the work piece, cutting and holding tool and eventually into the machine spindle. The effects on the application may be that the tool and the work piece will extend somewhat and tolerances can be in danger.
This problem can be solved in different ways. As have been discussed earlier, it is much more favorable for the die or mould accuracy to split roughing and finishing into separate machine tools. The heat conducted into the work piece or the spindle in finishing can be neglected. Another solution is to use a cutting material that does not conduct heat, such as cermets. In this case the main portion of the heat goes out with the chips, even in conventional machining.
It may sound trivial, but one of the main factors for success in HSM applications is the total evacuation of chips from the cutting zone. Avoiding recutting of chips when working in hardened steel is absolutely essential for a predictable tool life of the cutting edges and for a good process security.Cutting fluid in HSM: The best way to ensure a perfect chip evacuation is to use compressed air. It should be well directed to the cutting zone. Absolutely best is if the machine tool has an option for air through the spindle.
(a) The second best is to have oil mist under high pressure directed to the cutting zone, preferably through the spindle.
(b) Third comes coolant with high pressure (approximately 70 bar or more) and good flow. Preferably also through the spindle.
(c) The worst case is ordinary, external coolant supply, with low pressure and flow.
4.0 COMPARISONS
4.1 Comparison between Conventional Machine and High Speed Machine:
Table.4.1: Comparison between Conventional Machine and High Speed Machine.
CONVENTIONAL MACHINE HIGH SPEED MACHINE
Maximum speed 600 m/min Maximum speed ~40 rpm Require high levels of coolant Speed starts at 600 m/min Feed starts at 100 rpm
With coolant, feed rate can go more than 2000 rpm
No feed for coolant for low feed rate.
4.2 Comparison between Conventional Machining and HSM process:
Table.4.2: Comparison between Conventional Machining and HSM process .
CONVENTIONAL HSM
The contact time between the cutting edge and work piece is large Contact time between the cutting edge and work piece is short
Less accurate work piece More accurate work piece
Cutting force is large Low cutting force
Cutting fluid is required Cutting fluid is not required
Low surface finish High surface finish
Material removal rate is low Material removal rate is high
4.3 : Comparison between High Speed Machining (HSM) and Electronic Discharge Machining (EDM) process.
Table.4.3: Comparison between High Speed Machining (HSM) and Electronic Discharge Machining (EDM) process.
HSM EDM
Material removal by interference between tool and work contact process Non contact process
Dimensional tolerance 0.02mm Dimensional tolerance 0.1-0.2
Material removal rate high Material removal rate low
5 Improvement of production process when using HSM:
The use of HSM allows us to shorten the production time and to increase the accuracy of machined parts. High Speed Machining is being mainly used in three industry sectors due to their specific requirements.
Fig.5.1: Improvement of production process when using HSM
(A) Traditional process. The steps are:
1. Non-hardened (soft) blank.
2. Roughing.
3. Semi finishing.
4. Hardening to the final service condition.
5. EDM process-machining of electrodes and EDM of small radii and corners of big depths.
6. Finishing of parts of the cavity with good accessibility.
7. Manual finishing.
B) Same process as A, where the EDM process has been replaced by finish machining of the entire cavity with HSM thereby reduction of one process step.
C) In this process:
1. Initially the blank is hardened to the final service condition.
2. Roughing.
3. Semi finishing.
4. Finishing.
5. Manual finishing.
Here the HSM most often applied in all operations and thereby reduction of two process steps. Normal time reduction compared to the process A is approximately equal to 30-50%.
The other benefits include reduced material handling cost, lower residual stress, increased productivity, possibility of machining of very thin walls, enhanced damage tolerance, shortened delivery times, elimination of coolant and increased cutting efficiency etc.
Bellow table shows the various effects due to the above features which positively impact the global manufacturing process chain with in a machine shop.
Table.5.1: Various effects due to the above feature:
Features Effects
Reduced heat transfer in to the work piece Part accuracy
Reduction of cutting forces Part accuracy, surface quality
Increased cutting speed Stability of rotating cutting tool feed rate, increased material removal
Graph below shows that the cutting force (Fc) decreases with increase in cutting speed (VC).
Graph.5.2: Fc vs. Vc for a constant cutting power of 10kw
Fc: Cutting Force
Vc: Cutting Speed
6.0 SAFETY PRECAUTIONS
6. .1 Safety precautions while machining:
• Check the machine condition before starting the work.
• Before starting the work clamp work-piece rigidly, with help of clamping device.
• Follow the company instructions.
• Do not play with machine.
• Without shoes do not enter the work shop.
• Do not use cell phones in work shop.
• Use cranes for loading and unloading of row materials, jobs, machines and finished products.
• Wear spectacle, apron while machining.
• Do not change or shift the gear while machine is in running condition.
• Do not check the work-piece when machine is running.
• Use high quality instruments for inspection.
• Use soft hammers for hammering on finished surface, assembled parts.Use coolant to prevent work-piece heat and also increasing the life of the cutting tool.
• Do not run the machine in idle condition.
• After working or machining clean the machine and surrounding.
• Apply or lubricate oil on moving parts of machine.
7. CONCLUSION
HSM is not simply high cutting speed. It should be regarded as a process where the operations are performed with very specific methods and production equipment HSM is not necessarily high spindle speed machining. Many HSM applications are performed with moderate spindle speeds and large sized cutters HSM is performed in finishing in hardened steel with high speeds and feeds often with 4-6 times conventional cutting data HSM is high productive machining in small sized components in roughing to finishing and in finishing to super finishing in components of all sizes Even though HSM has been known for a long time, the research is still being developed for further improvement of quality and optimization of cost.
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