HFC milling: Roughing and prefinishing at high feed rates
Best results with precise residual stock calculation
High feed-rate cutters (HFC tools) can be used to achieve a high cutting capacity at very high feed rates and cutting speeds. These high-performance cutters have a special cutter geometry with multiple cutting edges. They are available with and without indexable inserts.
Two examples of high feed-rate tools: A tool with four edges (left) and one with indexable inserts (right).
The great advantage with Tebis: Because the actual contour of the tool is used for programming, milling areas up to the residual stock are precisely calculated. The real tools can be represented one-to-one in the virtual tool library.
In conventional programming , toroidal substitute geometries (3) are used for programming instead of the actual contour of the tool (2). Geometry (1) is not correctly contacted. Material contact cannot be accurately defined, and residual stock will remain (4).
In Tebis, the actual tool contour of the HFC tool (2) is used for programming. Geometry (1) is contacted with high precision. After prefinishing, the only material remaining is in areas that cannot be machined with the selected tool. This allows HFC tools to be optimally employed – and not just for roughing but also for prefinishing.
HFC machining in a practical test: High-feed cutters are especially cost-effective when they are correctly used for roughing, finishing and residual stock machining. This video demonstrates how machining time can be reduced by up to 50 percent with the overall package of Pokolm high-feed cutters and Tebis CAM software.
Prefinishing a draw die for a side panel is also much faster with HFC tools than with traditional ball and torus cutters. See for yourself in our comparison video!
This water jacket mold was manufactured with Tebis NC programs using HFC tools and high-precision contact geometry on a 5-axis GROB G550 machine with the new MMC Hitachi Tool GF1 barrel-cutter with indexable inserts.
Your benefits in the overall process
- Precise calculation of residual stock
- Long tool life
- Up to 50 percent faster machining times
- Higher cutting speed and feed rates
- Maximum material removal rate
- Precise NC paths
- Highly efficient and reliable manufacturing
- High process reliability
- Shorter machining time
- Lower manufacturing costs
The latest generation of tools also includes the "MHTE Gallea New Tool Series GP1LB" from Mitsubishi Hitachi Tool Engineering, Ltd. These tools combine three geometries in a single tool. This permits the machining of different slope areas within a geometry using only a single tool. These tools integrate perfectly with TebisDiese Werkzeuge: In Tebis, the model can be split up into different milling areas based on the slope in Tebis using special CAD functions. These areas can then be machined in a single pass using different strategies and stepovers. Ultimately, the components are not just finished quicker; they are also of much higher quality. When combined with modern high feed-rate technology and high-precision contact geometry, the results are even better. Tebis collaborates very closely with tool manufacturer Mitsubishi Hitachi Tool Engineering, Ltd. and machine manufacturers Mitsubishi Heavy Industry Machine Tool Co., Ltd. and SNK in Japan. Tebis and its partners demonstrated how perfectly Tebis is matched to tools and machines at the 2016 JIMTOF trade show in Tokyo.
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