Faster manufacturing with HFC tools

    Suitable for roughing and prefinishing

    High feed cutters or  HFC tools  (high feed cutting) enable high cutting performance with high feed rates and cutting speeds on modern milling machines. These high feed cutters and high-performance cutters have a special cutter geometry with multiple cutting edges. They’re available with and without indexable inserts.

    These tools can be implemented extremely efficiently in combination with Tebis for both roughing and prefinishing: NC programming in Tebis is always performed using the real cutter geometry, and the maximum possible residual stock is removed – the optimal preparation for final finishing.

    Two examples of high feed-rate cutters for HFC milling: A tool with four edges (left) and one with indexable inserts (right).
    Maximum material removal with precise calculation of residual stock • High-precision NC paths
    Machining time reduced by up to 50 percent • Lower manufacturing costs because of longer tool life
    High process reliability with digital twin of the actual tool

    Precise calculation of residual stock

    The significant advantage of HFC cutters in Tebis: Because the actual contour of the tool is used for programming, milling areas up to the residual stock are precisely calculated. The actual tools can be represented by a one-to-one digital twin in the virtual tool library.

    That makes the difference

    Conventional programming uses toroidal substitute geometries (3) instead of the actual tool contour (2). Geometry (1) is not correctly contacted. Material contact cannot be accurately defined, and residual stock will remain (4). 

    In Tebis, the actual tool contourof 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

    Practical examples from all sectors

    HFC milling in a practical test: High-feed cutters are especially cost-effective if they are implemented correctly in roughing, finishing and residual stock machining. This video demonstrates how machining time with HFC cutters can be reduced by up to 50 percent with the complete package of Pokolm high-feed cutters and Tebis CAM software. 

    With HFC cutters, prefinishing a draw die for a side panel is also much faster with 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.

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    CNC Simulator

    The Tebis CNC Simulator lets you fully plan, program and check your NC machining operations in the Tebis CNC programming environment. All of the components in your real manufacturing environment – including tools, machines, clamping devices and units – are stored down to the last detail as digital twins in the virtual programming environment. 

    High-efficiency roughing

    Compared with conventional roughing, time savings of over 60 percent can be achieved with adaptive roughing using special HPC cutters with very large cutting depths. The path layout is perfectly adapted to the geometry with no full cuts. 

    Circle-segment cutters

    Circle-segment cutters have a special geometry that saves you up to 80 percent of the time required for prefinishing and finishing compared to machining with ball cutters. Tebis supports all these kinds of efficient high-performance tools – because each tool can be modeled with precise attention to detail in the virtual CAM environment.