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passionpassionfor precisionfor precisionFRAISA High Dynamic Cutting HDCHigh dynamic cutting withconstant cutting edge utilisationnewcutting data calculatorToolExpertHDC
More productive thanks to FRAISA HDCFRAISA uses FRAISA HDC toprovide the data for the highdynamic cutting strategy.Most CAM systems allow the calculation of tool paths for high dynamiccutting. These high-speed roughingstrategies are described verydifferently by CAM system suppliers,but have one important thing incommon: during the operation,cutting conditions (machining forcesand temperature) are kept constant.[2]Through the use of high-speed roughing strategies, the metal removalrate can be increased enormously(factor of 2 compared to conventionalHPC machining). This reduces themachining times. Furthermore,tool wear is significantly lower dueto the constant cutting conditions.This results in longer tool life, whencompared to conventional cuttingstrategies. Process reliability is alsopositively influenced.5 elements for a safe and efficient HDC processFRAISA1CAM ancetools5HDC cutting dataUserObjectives:- Increasing productivity- Reducing tool costs- Improving process reliabilitySUMMARY: FRAISAHDC allows efficientmilling with highprocess reliability.FRAISA provides you with the righttools, cutting data, and the applicationexpertise to suit your machinery,and gives you advice on how toimplement the FRAISA HDC high-speedcutting strategy.
Table of contentsComparison between HPC and HDC4Advantages of HDC.4HPC vs. HDC (advantages and disadvantages).5Five elements for the successfulimplementation of FRAISA HDC[3]6CAM software.8Machinery .10HDC application.11Tool (NX-NVD & NB-NVD).12Cutting data.13FRAISA ToolSchool seminars14
Advantages and comparison of theHPC and HDC roughing processesFor HDC machining, FRAISA provides:[4] ToolExpert HDC: Online tool for calculating cutting datafor high dynamic cutting High-performance tools that fulfil the requirementsfor HDC machining Seminars to teach the implementationof HDC strategiesMachining processes canbe accelerated using theHDC strategy, reducing theload on tools and makingoptimal use of the availablemachinery.Result: Greater productivityand increased efficiency, atsignificantly lower costs.Work more productivelywith ToolExpert HDCService –we will be happy to advise youTools –designed for HDCProductivity in your company can besignificantly increased with the newHDC roughing strategy.With seminars, training coursesand workshops, we can help youintegrate high dynamic cuttinginto your production process.Our application engineerswill be happy to advise you.High-performance tools whose specialproperties make them ideal fordynamic machining.FRAISA provides a new cutting datacalculator that enables effectiveimplementation of HDC machining.The use of this online tool makescalculating the cutting data fordynamic machining quick and easy.
AdvantagesThe following table compares the most frequently usedconventional cutting strategy, HPC, with the HDC highdynamic cutting strategy.Conventional cuttingHigh Dynamic CuttingHigh Performance Cutting – HPCHigh Dynamic Cutting – HDC High metal removal rate Low tool wear Chips are simple to remove Large cutting depths possible H igh performance on stable,high-performance machines Very high metal removal rate Use of profiled tools is possible Short tool paths Low thermal loading of tool cutting edges High process reliability Low power consumption by the machine spindle Very economical, even at low cutting depths(ADOC 1*d) Machining with flexible clamping possible Generally high machining forces Programming system (CAM) requiredDisadvantages High consumption of spindle power Suboptimal utilisation of cutting tool potential due tolimitation of the application data at the most criticalmachining areas High wear over a small portion of the cutting edge[5]Advantages of FRAISA HDC: Faster machining times and higher productivity due to higher cutting speeds and feed rates Constant metal removal rate and constant cutting conditions during the machining processincrease process reliability Gentle, rounded tool paths and constant machining temperatures at the cutting edge protectthe tool against wear, thereby increasing tool life and reducing tool costs Strategy and application data can be adapted to the machinery available:optimal utilisation of machinery with optimal machining, even of delicate components Improved optimisation: due to high process reliability and longer tool life
Five elements for the successfulimplementation of FRAISA HDCThe following five elements enable you to successfullyimplement FRAISA HDC:[6]1 CAM software2 Machinery3 HDC application4 High-performance tools5 HDC cutting dataThe first element for the use of the HDC roughingstrategy is a CAM system, which allows the generation ofthe tool paths required. In the second and third elements,the HDC application is defined on the basis of themachinery available.The next elements for the implementation of the HDCstrategy are the right tools and the associated cutting data.Consequently, FRAISA provides products that are optimallydesigned to fulfil the requirements of the HDC strategy.The new ToolExpert HDC cutting data calculator from FRAISAdetermines the appropriate cutting data on the basis of thematerial, the application, and the tool.
5 elements for a safe and efficient HDC processFRAISA1CAM softwareGeneration oftool paths for highdynamic cutting ona CAM system2MachineryEvaluation andclassification of theexisting machinery3HDCapplicationDetermination ofthe application onthe basis of themachinery available4High-performancetoolsSelection of the toolfor HDC machining5HDC cutting dataCalculation of thecutting data usingFRAISA ToolExpertHDC[7]UserUserObjectives:- Increasing productivity- Reducing tool costs- Improving process reliability
The individual elements in detail1 CAM software[8]Most CAM systems have modules for implementingthe HDC high dynamic cutting strategy. The names of themodules vary from supplier to supplier.Overview of CAM suppliers and the names of the modulesfor the HDC high dynamic cutting strategy*AlphaCAM Wave machiningCeleritive Technologies (Camworks , Cimatron ,Gibbscam , Siemens NX )VoluMill Delcam Vortex EdgeCAM Wave-shaped strategyESPRIT ProfitMilling HSMWorks / VisiCAM Adaptive Clearing InventorCAM iMachining Mastercam Dynamic Milling(Dynamic Mill )OpenMind HyperMaxx(VoluMill )Siemens NX Adaptive Milling SolidCAM iMachining SurfCam TrueMill Topsolid Boost Milling * This list of product names makes no claim of entirety.
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2 MachineryHigh dynamic machines withlimited spindle powerDynamic, high-performancemachinesSpeedMaximum productivity is achieved in a refinedmachining environment, in which optimal use canbe made of high cutting speeds and feed rates.High-speed machining centres with high machinedynamics and wide spindle speed ranges are thereforesuitable. The low cutting forces generated in themachining process permit adaption for machiningdelicate components and flexible clamping.As with the HPC strategy, maximum productivity isachieved in a machining environment designed for highcutting forces. High-performance machining centrestogether with robust workpiece clamping and short sidelock tool holding are fundamental.MachineryMachineryWide spindle speed rangeHigh-performance milling spindleHigh machine dynamics (linear)Moderate machine dynamics (Ball screw actuation)Milling spindle with low torqueModerate spindle speed rangeDelicate machine structure (low mass)Stable machine structure (large ting:Flexible systemSetting:ViceClamping system:ShrinkfitClamping ationApplicationHigh Performance Dynamic CuttingHigh Speed Dynamic CuttingHDC-SHDC-PThe right machinery for the right applicationCutting force and feed rate depending on lateral infeed at a constantmetal removal ratelargeSpeedPerformanceHigh dynamic machinesHDC-SHDC-Psmall 0highFeed rateMachining forces[ 10 ]Performance5101520RDOC/%25303540low
3 HDC applicationOn the basis of the machinery, we differentiatebetween two HDC applications:In the case of HDC-P, higher cutting forces are generatedwith slightly lower milling dynamics. In the case of HDC-S,the high dynamics of the machine are used for high-speedcutting. In both applications, approximately the samemetal removal rates can be achieved.High Speed Dynamic Cutting – HDC-SHigh Performance Dynamic Cutting – isticsCharacteristicsRadial infeed 5% – 10% of the tool diameterRadial infeed 15% – 25% of the tool diameterAxial infeed up to 3.5 x tool diameterAxial infeed up to 2.5 x tool diameterThe HDC-S application is a combination of HPC and HSCmachining strategies.The high performance of HPC cutting is combinedwith the very high cutting speeds and feed ratesof HSC cutting. HDC-S can therefore be seen as acounterpart to HDC-P, with smaller radial infeed andhigher cutting speeds and feed rates.Tool pathsThis application is similar to HPC. However, duringHDC-P the tool paths are generated by a CAM systemand the machining conditions are precisely defined andkept constant. This enables higher cutting speeds andfeed rates to be used with smaller radial infeeds.Tool paths[ 11 ]
4 High-performance toolsFor HDC applications, tool selection is very important.The tool needs to have a high level of stability and anormal or medium-length cutting edge to be suitable forthis process. The NVD tool group NX-NVD and NB-NVDis ideally suited for HDC applications, particularly becauseof the following characteristics. High rigidity and stability due to tapered core High resistance to fracture Vibrations avoided because of the variable helix Good chip evacuation because of the double groove geometryOverview of application suitability[ 12 ]Our E-Shop can be found at fraisadirect.com.Further information on individual tools can be found in the catalogue, or in the product brochureat fraisa.com/us/products/end-milling-tools.The fastest wayto our E-Shopcan be found here.
5 HDC cutting dataFRAISA ToolExpert HDC[ 13 ]In the fifth element, HDC cutting data is calculated.FRAISA has developed ToolExpert HDC and made thecalculation program available online.ToolExpert HDC enables the user to calculate cutting data forthe HDC strategy in a simple manner.Success is guaranteed.You can find the cutting data in our ToolExpert HDC,and on our homepage fraisa.com/us, or simply follow the direct link:fraisa.com/toolexpert-hdc/us
FRAISA machining seminarsLearn more about HDC machiningat ToolSchoolFRAISA machining seminars[ 14 ]We will be happy to provide you with information about ouryearly FRAISA machining seminars. As always, the machiningseminars are held in the United States (Minnesota).In the FRAISA technology seminars, highly qualified engineers train the technical and management staff of specificindustries. At the end of the seminar a personal certificate ispresented to confirm your participation.You can find additionalinformation about theseminars here.We are happy to advise you, and provideyou with further information on theseminars and registration process atinfo@fraisausa.com or online atfraisa.com/us/services/toolschool.
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Here, you will be providedwith further informationon the FRAISA Group.The fastest wayto our E-Shopcan be found here.FRAISA USA, Inc.711 5th Street SW, Ste. 1 I New Brighton, MN 55112 ITel: 1 (651) 636 8488 I Fax: 1 (651) 636 8588 IToll Free: 1 (800) 427 7114 Iinfo@fraisausa.com I www.fraisa.com/us IYou can also find us ionpassionfor precisionfor precision
Mastercam Dynamic Milling (Dynamic Mill ) OpenMind HyperMaxx (VoluMill ) Siemens NX Adaptive Milling SolidCAM iMachining SurfCam TrueMill Topsolid Boost Milling * This list of product names makes no claim of entirety. [ 8 ] [ 9 ] As with the HPC strategy, maximum productivity is achieved in a machining environment designed for high cutting forces. High-performance .
