High-efficiency roughing with HPC milling machines

    High-performance cutting (HPC) for maximum material removal rate

    The goal of every roughing operation is to remove as much material as possible within the shortest possible time. This is an enormous stress test for the cutter, which often ends up in full contact. Tebis therefore uses options for full-cut handling as well as for full-cut avoidance. In full-cut handling, feed rates are automatically reduced, or full-cut areas are machined trochoidally. In full-cut avoidance, the path layout is automatically adapted to the geometry without full cuts.

    Full-cut avoidance is used in adaptive roughing. This is where it really counts: Compared with conventional roughing, special HPC cutters achieve extremely high material removal rates at constant cutting conditions with higher cutting speeds and feed rates, smaller lateral stepovers and very large cutting depths – and time savings of over 60 percent are easily possible. Adaptive roughing strategies for HPC milling are especially suitable for parts with many deep cavities. Hard materials can also be machined very easily in this way. 

    HPC cutters with long cutting edges for large downfeed
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    Adaptive roughing of free-form pockets

    HPC milling with Tebis

    Highly efficient
    Feed rates and paths are always optimized • Longer machine uptime • Lace cut machining is also possible
    An end-to-end system
    Blank tracking across machining operations
    Protects tool materials
    Long tool life

    Suitable for 2.5 D, 3D and 5-axis machining operations

    Adaptive trochoidal roughing strategies can be implemented in Tebis in 2.5D, 3D and 5-axis machining operations. The tool can be quickly repositioned, even at high feed rates. Integrated blank transfer enables a simple combination of all milling operations. 

    2.5D HPC roughing

    3D HPC roughing

    5-axis simultaneous HPC roughing

    Integrated re-roughing for even better results

    The additional "Re-roughing upwards" option enables remachining of residual stock areas with a smaller depth of cut from the bottom upwards with no difficulties. 

    Clear pocket adaptively or trochoidally in a single step...

    ... Machine residual stock on the pocket walls...

    ... from bottom to top.

    How it’s done! Practical test of run time calculation

    Without a doubt: The adaptive roughing strategy is the one that achieves the highest material removal rate. In many cases it is also the most efficient strategy – but not always. Because how a part is best machined depends on the geometry, the material and the machine tool. Technology parameters such as cutting data and feed rates must exactly match the machining operation. 

    In our practical test, we compared different roughing strategies taking part geometry and the technology parameters into account. Results: The right combination is critical!


    For everyone who wants to learn more

    Webinars, technical articles ...

    Improve manufacturing efficiency with high-performance tools

    In our webinar, we showed how you can benefit from modern high-performance tools such as HPC and circular segment milling cutters and how Tebis supports these tools. Exact virtual tool contours and the ability to combine all machining types and strategies as you wish ensure optimal results.

    Webinar recording (German)
    Manufacturing more efficiently with modern high-performance tools

    You want faster roughing and finishing? And not only 5, 10, 15 or 20 percent faster, but even faster than that?

    Read the technical article

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    Related topics

    3D milling

    Free-form machining lets you combine all your strategies for roughing, finishing and residual stock machining in the Tebis Job Manager. You can use convenient template technology and ensure collision avoidance already in the CAM environment.

    5-axis milling

    Tebis 5-axis milling lets you use the full potential of your expensive high-performance machines: Collision-free programs can be easily planned and calculated for all multi-axis machining operations. Simultaneous 5-axis strategies that are customized for specific manufacturing tasks make NC programming very simple – especially in combination with Tebis template technology. 

    2.5D milling

    Prismatic machining can be completely automated based on individual process libraries using Tebis template technology. Programming on the machine is eliminated and NC programming at the Tebis workstation is simple.

    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. 

    HFC milling

    HFC tools allow you to achieve high machining rates at high feed rates. Tebis calculates the residual stock with absolute precision: The maximum amount of possible material is removed. HFC tools can therefore be used optimally with Tebis, not only for roughing but also for prefinishing. 

    CAM software for many manufacturing methods

    Tebis CAD/CAM software lets you quickly, easily and automatically create collision-free NC programs for many manufacturing methods – including drilling, milling, turning, turning/milling, robotic milling, trimming, sinker EDM, wire EDM, 3D laser cutting, laser hardening and laser weld cladding.

    CNC automation
    Tebis Automill® evaluates the digital CAD part model and accesses a previously stored structure of digital representations of the company's manufacturing environment and the manufacturing knowledge stored in templates to calculate the NC programs.