Faster and more efficient with High Feed Milling
There are a number of excellent reasons to use High Feed Milling. Here are a few tips to get you started.
High Feed Milling is fast. It’s designed to remove as much material as possible in the shortest amount of time. In fact, it can almost triple the amount of material removed compared to machining with conventional methods.
Not only does High Feed Milling increase productivity by removing material faster, but it also achieves this with greater stability, extending tool life. Jörgen Andersson, Product Manager, Copy Milling, explains, “High Feed Milling is less sensitive to vibrations due to axially directed forces than ordinary milling methods, which means that you can keep up the feeds even in long tool overhangs.”
Even with the increased productivity, High Feed Milling consumes less energy than conventional milling, while removing the same amount of material.
High Feed Milling is mainly used as a roughing method and it can be applied in all kinds of applications and materials. It can be found in all industrial segments, especially within aerospace, die and mould, and general engineering. “The more difficult the materials are to machine, the more beneficial it is to use High Feed Milling,” says Andersson.
The decision on whether or not to use High Feed Milling also comes down to the application. “High Feed Milling is especially recommended if you have difficult-to-machine materials or if you have long overhang on the tools, for instance when you have deep cavities to mill,” says Andersson.
Seco Tools has been expanding its portfolio of tools for High Feed Milling to match every application. The company was one of the first on the market to offer High Feed Milling solutions. Demand has risen sharply since the first product family was launched in 2003, the R217/220.21-Rxxx range with 218.19 inserts. “Today, we’re also adding double-sided high feed insert solutions, so that we can offer high-performing solutions that are also more cost effective,” says Andersson. “The double-sided solution means that you can multiply the number of edges, provided that you don’t have sticky materials or require a lot of ramping. In that case, the double-sided solutions can have some limitations in performance.”
A number of factors must be considered to get the most out of the High Feed Milling strategy, and it’s here that Seco Tools’ expertise can help. “We look into what kinds of machines are being used, the machining applications, the materials and what is being manufactured when we recommend a tool so that we provide each customer with the best possible solution,” Andersson says.
Despite such support and the many advantages of High Feed Milling, there is still some hesitancy to use it. Andersson believes some people are fearful that it will cause their machines to break down. However, he dispels this fear. “In my opinion, it’s more beneficial for machines to run with High Feed Milling tools because the power consumption in the machine goes down, meaning less stress on the machine and longer life.” Above all, says Andersson, “Don’t be afraid of High Feed Milling!”
By Cari Simmons Photos by Jonas Gauffin
High Feed Milling is recommended if
… You have problems with vibrations
… You want to increase productivity
… You are roughing hardened materials and super alloys.
How it works
High Feed Milling is a milling method that pairs shallow depth of cut with high feed per tooth, which provides higher metal removal rates, resulting in more parts being machined. The cutting forces are directed at the machine spindle in the axial direction, meaning greater stability and reduced vibrations, extending tool life.
The most common use for High Feed Milling is in hard-steel intense industries, such as aerospace and engineering, where the method is used for roughing, the first step in the metalworking process.