Ultra-High-Speed Machining: Notes on Metal Cutting at Speeds up to 7300 Ft/s
An earlier study of UHSM (V > 500 ft/s) by the author showed that metal cutting at such speeds should theoretically be beneficial for certain workpiece materials, and described experimental cuts in the range 1770 < V < 5200 ft/s. In the present study this range is extended to 7300 ft/s by cutting aluminium with HSS tools at depths of cut from 0.003 to 0.070 in, and 0.250 in width. To do this the suitably modified ballistic test system at Monash University was used to its operational limits. It was found that the extreme dynamic effects at the tool tip cause severe chipping and/or fracture. However, good cuts are still achieved, as was the case in the previous tests, whereas chip analysis becomes increasingly difficult. These effects are discussed and some comments on the practical application of UHSM are given.
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