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Milling tools for modern steel roughing
For nearly two decades, high-speed cutting (HSC) has been closely associated with fast production and efficient processing. However, in recent years, the focus has shifted toward a new concept: High-Performance Cutting (HPC). This term represents not just faster machining, but a broader strategy aimed at improving productivity while reducing overall costs.
HPC milling is defined as a process that significantly increases metal removal rates—by 200% to 500% compared to traditional methods. In a more comprehensive sense, HPC also involves optimizing the entire manufacturing chain to cut production costs by up to 30%. Unlike HSC, which primarily focuses on increasing cutting speed, HPC takes a more holistic approach by enhancing feed rates, tool design, and machine capabilities.
One of the key differences between HPC and HSC lies in their objectives. While roughing in HSC aims to maximize metal removal rate, it is often limited by tool geometry and machine rigidity. To improve efficiency, HPC leverages advanced tool designs, such as contoured cutting edges, to reduce cutting forces and improve tool life.
Experiments have shown that tools with formed cutting edges can reduce cutting forces by up to 23.5%, making them ideal for high-performance applications. However, these tools are more prone to wear and chipping under high feed rates and heavy loads. This highlights the need for careful selection of cutting edge geometries based on material properties and machining conditions.
In the case of high-strength steels, such as those with 68 HRC hardness, the choice of cutting edge becomes even more critical. A negative rake angle of -10° is often used to minimize mechanical stress and prevent chipping. Large wedge angles and high helix angles further help balance the cutting forces and improve chip evacuation, especially when working with brittle materials.
Figure 1 illustrates the difference in cutting forces between formed and non-formed tools, showing how optimized geometries can lead to better performance. Similarly, Figure 2 highlights the wear patterns on different types of cutting edges, emphasizing the importance of tool design in maintaining efficiency and longevity.
When it comes to high-performance cutting, selecting the right tool geometry is essential. Whether using smooth or selective cutting edges, the goal is to achieve a balance between cutting efficiency, tool life, and machine stability. The NX, HX, and SX tool series are designed to handle a wide range of steel grades, from 54 HRC to higher hardness levels, demonstrating the versatility of HPC technology.
Compared to HSC, HPC offers greater flexibility and performance, especially in complex machining operations. By combining advanced tooling with optimized cutting parameters, HPC enables manufacturers to achieve faster, more cost-effective results. This makes it a valuable solution for industries looking to enhance productivity without compromising quality.