? Cell controller

? Programmable logic controller (PLC)

? More than one machine tool

? A materials handling device (robot or pallet)

The FMC executes fixed machining operations with parts flowing sequentially between operations. 

High speed machining

The term High Speed Machining (HSM) commonly refers to end milling at high rotational speeds and high surface feeds. For instance, the routing of pockets in aluminum airframe sections with a very high material removal rate1. Over the past 60 years, HSM has been applied to a wide range of metallic and non-metallic workpiece materials, including the production of components with specific surface topography requirements and machining of materials with hardness of 50 HRC and above. With most steel components hardened to approximately 32-42 HRC, machining options currently include: Rough machining and semi-finishing of the material in its soft (annealed) condition heat treatment to achieve the final required hardness = 63 HRC machining of electrodes and Electrical Discharge Machining (EDM) of specific parts of dies and moulds (specifically small radii and deep cavities with limited accessibility for metal cutting tools) finishing and super-finishing of cylindrical/flat/cavity surfaces with appropriate cemented carbide, cermet, solid carbide, mixed ceramic or polycrystalline cubic boron nitride (PCBN)

For many components, the production process involves a combination of these options and in the case of dies and moulds it also includes time consuming hand finishing. Consequently, production costs can be high and lead times excessive.

It is typical in the die and mould industry to produce one or just a few tools of the same design. The process involves constant changes to the design, and because of these changes there is also a corresponding need for measuring and reverse engineering . 

The main criteria is the quality level of the die or mould regarding dimensional, geometric and surface accuracy. If the quality level after machining is poor and if it cannot meet the requirements, there will be a varying need of manual finishing work. This work produces satisfactory surface accuracy, but it always has a negative impact on the dimensional and geometric accuracy.

One of the main aims for the die and mould industry has been, and still is, to reduce or eliminate the need for manual polishing and thus improve the quality and shorten the production costs and lead times.

Main economical and technical factors for the development of HSM

Survival

The ever increasing competition in the marketplace is continually setting new standards. The demands on time and cost efficiency is getting higher and higher. This has forced the development of new processes and production techniques to take place. HSM provides hope and solutions...

Materials

The development of new, more difficult to machine materials has underlined the necessity to find new machining solutions. The aerospace industry has its heat resistant and stainless steel alloys. The automotive industry has different bimetal compositions, Compact Graphite Iron and an ever increasing volume of aluminum3. The die and mould industry mainly has to face the problem of machining high hardened tool steels, from roughing to finishing.

Quality

The demand for higher component or product quality is the result of ever increasing competition. HSM, if applied correctly, offers a number of solutions in this area. Substitution of manual finishing is one example, which is especially important on dies and moulds or components with a complex 3D geometry.

Processes

The demands on shorter throughput times via fewer setups and simplified flows (logistics) can in most cases, be solved by HSM. A typical target within the die and mould industry is to completely machine fully hardened small sized tools in one setup. Costly and time consuming EDM processes can also be reduced or eliminated with HSM.