Abele, Eberhard ; Pfeiffer, Patrick ; Schäfer, Dominik (2012):
High Speed Machining: Still a challenge for large scale and widespread industrial applications.
9th International Conference on High Speed Machining 2012 - Innovations in Machining, Spain, San Sebastian, [Conference or Workshop Item]

Abstract

The fundamentals of High-Speed-Machining (HSM) are clarified within the last 20 years and many effective industrial HSM-applications are state of the art. However, still a lot of machining processes like deep hole drilling and machining Difficult-To-Cut (DTC) materials, e.g. titanium and compacted graphite iron (CGI), are challenging to implement successful HSM strategies. The paper briefly introduces the fundamentals of HSM and mainly focuses on current research activities while machining titanium, steel and cast iron materials. By trend, automotive engine designers create their products out of higher strength cast iron materials with improved mechanical properties. Hereby machining of compacted graphite iron (CGI) is challenging. Cryogenic machining in combination with polycrystalline diamond tools could be reasonable to bridge the gap to large scale production and to overcome the difference in productivity comparing CGI and conventional grey cast iron machining. Furthermore, high speed drilling (HSD) using extra-long twist drills is challenging. A major problem is the torsional chatter, which must be prevented to improve the drilling process at high cutting speed. Therefor the analysis of chattering-effects is an adequate way for simulation and prediction of torsional chatter during the HSD-process with overlong drills. The optimization of cutting tools and parameters for the mentioned HSM-applications is as important as the analysis of occurring heat and appropriate cooling strategies to achieve the aim of high productivity levels while reaching outstanding tool life times and machining qualities.

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