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Milling tools for modern steel roughing
For nearly two decades, high-speed cutting (HSC) has been synonymous with fast and efficient production. However, in recent years, the industry has shifted its focus toward a newer concept known as High-Performance Cutting (HPC). This evolution represents not just a change in terminology, but a transformation in how we approach machining processes to maximize efficiency and reduce costs.
HPC milling is often described as a process that significantly increases metal removal rates—up to 200% to 500% higher than traditional methods. More broadly, HPC aims to optimize the entire manufacturing chain, targeting cost reductions of 10% to 30%. Unlike HSC, which primarily focuses on increasing cutting speed, HPC takes a more holistic approach by improving feed rates, tool geometry, and machine capabilities.
In roughing operations, the goal is typically to maximize material removal. While HSC relies heavily on increasing cutting speed, this approach is often limited by technical constraints. HPC, on the other hand, looks to increase both the number of cutting edges and the feed rate. However, this can lead to higher mechanical loads on the tool, especially when using high feed rates at a fixed cutting speed. The resulting forces can stress the machine tool and require more robust equipment.
Experiments have shown that tools with contoured cutting edges can reduce cutting forces by up to 23.5%, making them an attractive option for HPC applications. However, these tools are prone to wear and chipping, especially under high feed rates and when machining hard materials. In contrast, non-formed carbide end mills are designed to handle higher forces and are more suitable for certain HPC applications.
When working with high-strength steels (e.g., 68 HRC), it's crucial to avoid excessive mechanical loads on the cutting edge. A negative rake angle of -10° is often used to improve tool strength, while a large wedge angle (over 90°) helps balance the cutting force. Additionally, a high helix angle (up to 55°) is beneficial for processing brittle, hard materials by reducing engagement forces.
The NX, HX, and SX series of HPC tools are designed for different applications and demonstrate significant performance advantages, especially when machining materials like 54 HRC steel. Compared to HSC, HPC allows for much higher metal cutting speeds, even when using similar feed rates per tooth. By optimizing cutting angles and groove geometries, HPC can cover the full range of steel machining, offering substantial benefits in terms of productivity and cost reduction.
Ultimately, HPC represents a smarter, more efficient way to machine difficult materials, transforming cutting speeds into real-world savings for manufacturers.