Copyright © 2007 Society of Manufacturing Engineers

MANUFACTURING INSIGHTS
High Speed Machining

SCENE 1. WARNING
HSM01A, CG: FBI warning
Federal law provides severe civil and
white text centered on black to blue
gradient criminal penalties for the unauthorized
reproduction, distribution or exhibition
of copyrighted media.
Copyright © 2007
Society of Manufacturing Engineers

SCENE 2. This program was produced using the technical

HSM02A, CG: M&MR/SME screen
resources of the Machining & Material Removal
white text centered on black to blue
gradient Community of SME.
For more information on high speed machining,
please visit our website at:
www.sme.org

SCENE 3.
HSM03A, SME logo, with music

SCENE 4. MUSIC UP AND UNDER

HSM04A, MI open, with music
HSM04B, peter carey narration NARRATION (VO):
HSM04C, tape 14, 17:13:32-17:13:56
zoom out, high speed machining MANUFACTURING INSIGHTS, MANUFACTURING
operation
HSM04D, CGS: High Speed Machining ENGINEERING MAGAZINE’S VIDEO SERIES FOR
HSM04E, blue background
PROCESS IMPROVEMENT. THIS PROGRAM EXPLORES

HIGH SPEED MACHINING TECHNOLOGY AND HOW IT’S

BEING EMPLOYED TO QUICKLY AND ECONOMICALLY

MACHINE QUALITY PRODUCTS.

SCENE 5. NARRATION (VO):

HSM05A, tape 10, 11:29:35-11:29:49
zoom in, high speed machining WE’LL FOCUS ON FOUR COMPANIES AND WHAT THEY’VE
operation
DONE TO SUCCESSFULLY IMPLEMENT AND APPLY HIGH

SPEED MACHINING SYSTEMS.

 Copyright © 2007 Society of Manufacturing Engineers

SCENE 6. NARRATION (VO):

HSM06A, CGS: Trutron Corporation
HSM06B, tape 02, 02:27:32-02:27:51 OUR FIRST STOP WILL BE AT TRUTRON CORPORATION.
zoom out, high speed machining
graphite AT FIRST, MANAGEMENT WAS SKEPTICAL THAT HIGH

SPEED MACHINING COULD DELIVER ON ALL THE

PERFORMANCE CLAIMS MADE.

SCENE 7. NARRATION (VO):

HSM07A, tape 02, 02:08:03-02:08:23
zoom out, high speed machining steel BUT ONCE EXPERIENCING ITS BENEFITS, TRUTRON

MANAGEMENT HAS EMBRACED HIGH SPEED MACHINING

AS A STRATEGIC DIRECTION FOR THEIR COMPANY.

SCENE 8. NARRATION (VO):

HSM08A, CGS: Protomatic Inc.
HSM08B, tape 05, 05:54:41-05:54:53 NEXT, WE'LL VISIT PROTOMATIC INCORPORATED, A
pan, machinists at machining centers
HIGH-QUALITY PROTOTYPE AND SHORT-RUN

PRODUCTION MACHINING COMPANY.

SCENE 9. NARRATION (VO):

HSM09A, tape 05, 05:05:09-05:05:30
zoom in, high speed machining PROTOMATIC BEGAN INVESTING IN HIGH SPEED
HSM09B, tape 08, 09:30:23-09:30:36
zoom out, gary speaking with doug on MACHINING TO OFFER MORE COMPETITIVE PRICING.
shop floor
BUT FIRST THEY HAD TO OVERCOME SOME COOLANT

AND TOOL VIBRATION PROBLEMS. FOR THIS,

PROTOMATIC RELIED ON OUTSIDE VENDORS TO

IDENTIFY THE PROBLEMS, AND FINE-TUNE THEIR

CUTTING PROCESS.

SCENE 10. NARRATION (VO):

HSM10A, CGS: Gosiger 3D
HSM10B, tape 13, 16:24:05-16:24:17 NEXT, WE WILL SEE HOW GOSIGER-3D, AN
software being used
HSM10C, tape 06, 06:07:12-06:07:28 APPLICATIONS ENGINEERING COMPANY IS WORKING
zoom in, high speed machining
HSM10D, tape 13, 16:03:03-16:03:12 WITH ITS CUSTOMERS TO REPLACE TIME AND COST
zoom out, high speed machined part
INTENSIVE PROCESSES SUCH AS JIG GRINDING, WIRE

'EDM' AND HAND FINISHING ENTIRELY WITH

 Copyright © 2007 Society of Manufacturing Engineers

HARDMILLING AND HIGH SPEED MACHINING. GOSIGER-

3D SAYS IT CAN IMPROVE THE QUALITY OF FINISHED

PRODUCTS WHILE SIGNIFICANTLY CUTTING

PRODUCTION TIME.

SCENE 11. NARRATION (VO):

HSM11A, CGS: Metlfab, Incorporated
HSM11B, tape 10, 11:02:22-11:02:37 AND FINALLY, WHEN METLFAB INCORPORATED WAS
pan of shop floor
HSM11C, tape 09, 10:09:51-10:10:05 LOOKING TO IMPROVE PRODUCTION, THE JOB SHOP
zoom out, high speed machining
HSM11D, tape 10, 11:29:09-11:29:25 HAD A UNIQUE NEED. THE COMPANY MAKES A LOT OF
zoom out, high speed machining
PROTOTYPES, MANY WITH TIGHT CORNERS AND SMALL

INTRICATE POCKETS. TO QUICKLY AND COST

EFFECTIVELY PRODUCE THESE PROTOTYPES, METLFAB

LOOKED AT EVERY ASPECT OF THEIR HIGH SPEED

MACHINING SYSTEMS TO MAXIMIZE PRODUCTION.

--- TOUCH BLACK ---

SCENE 12. NARRATION (VO):

HSM12A, tape 06, 06:04:08-06:04:38
zoom in, high speed machining THE TERM HIGH SPEED MACHINING, OR 'HSM', HAS
operation
BEEN IN THE LEXICON OF MANUFACTURING TERMS FOR

A LONG PERIOD OF TIME, BUT THE PROCESS HAS

ONLY GAINED IN ACCEPTANCE IN RECENT YEARS.

SCENE 13. NARRATION (VO):

HSM13A, tape 14, 17:21:27-17:21:50
zoom in, high speed machining THIS INCREASING RECOGNITION IS DUE TO HIGH
HSM13B, CGS: Reduce Cycle Times
Increase Throughput SPEED MACHINING’S SYNTHESIS OF TECHNOLOGICAL
Shorten Machining Time
Minimize Non-Machining ADVANCES THAT, WHEN COMBINED, ALLOW
Time
HSM13C, tape 11, 13:03:14-13:03:23 MANUFACTURERS TO REDUCE CYCLE TIMES,
zoom out, parts produced using high
speed machining INCREASE THROUGHPUT,

SHORTEN MACHINING TIME,

AND MINIMIZE NON-MACHINING TIME WHILE YIELDING

 Copyright © 2007 Society of Manufacturing Engineers

HIGH PRECISION PARTS HAVING A FAVORABLE

COST/PERFORMANCE RATIO.

SCENE 14. NARRATION (VO):

HSM14A, tape 15, 18:02:00-18:02:15
zoom out, high speed machining TYPICALLY, HIGH-SPEED MACHINING IS
HSM14B, tape 10, 11:32:39-11:33:00
fast high speed machining ACCOMPLISHED USING SPINDLE SPEEDS THAT RANGE

BETWEEN 12,000 TO 30,000 RPM AND HIGHER. THESE

SPINDLE SPEEDS ARE COUPLED WITH RAPID AXIS

MOVEMENTS, TRANSVERSE RATES, ACCELERATIONS,

AND DECELERATIONS TO MAXIMIZE MATERIAL

REMOVAL. GENERALLY, HIGH SPEED MACHINING IS

PERFORMED USING A SHALLOW AXIAL DEPTH OF CUT

IN ORDER TO ACHIEVE GOOD SURFACE FINISH WHILE

AVOIDING DAMAGE TO THE WORKPIECE, CUTTING

TOOL, OR SPINDLE.

SCENE 15. NARRATION (VO):

HSM15A, tape 02, 02:25:22-02:25:44
zoom out, high speed machining BUT HIGH SPEED MACHINING IS MUCH MORE THAN

SIMPLY RUNNING A CUTTING TOOL AT MAXIMUM FEED

RATES AND TAKING MULTIPLE SHALLOW CUTS. IN

FACT, THIS APPROACH TO MACHINING CAN BE LESS

EFFICIENT THAN TAKING FEWER PASSES HAVING

SOMEWHAT GREATER DEPTHS.

SCENE 16. NARRATION (VO):

HSM16A, tape 10, 11:18:19-11:18:31
zoom out, worker removing part from THE ULTIMATE GOAL OF HIGH SPEED MACHINING IS
high speed machine
HSM16B, tape 14, 17:19:52-17:20:21 TO PRODUCE A FINISHED PART IN THE LEAST AMOUNT
zoom out, high speed machining
operation OF TIME. THIS IS ACCOMPLISHED BY REDUCING
HSM16C, CGS: Machining Center
Tooling INEFFICIENCIES IN THE CUTTING PROCESS, BY
Programming/Software
MAXIMIZING THE RELATIONSHIP BETWEEN SPEEDS,
 Copyright © 2007 Society of Manufacturing Engineers

FEEDS, AND DEPTH OF CUTS AND BY COMPLETELY

INTEGRATING THE VARIOUS TECHNOLOGIES THAT

ENCOMPASS THE HIGH SPEED MACHINING CENTER,

IT’S TOOLING,

AND THE PROGRAMMING AND SOFTWARE.

--- TOUCH BLACK ---

SCENE 17. NARRATION (VO):

HSM17A, CGS: Machining Center
HSM17B, tape 14, 17:27:53-17:28:09 THERE ARE A VARIETY OF ADVANCED HIGH SPEED
pan, high speed machines
MACHINING CENTERS AVAILABLE. THE BEST ARE

CHARACTERIZED BY A COMPACT, RIGID, AND ROBUST

DESIGN.

SCENE 18. NARRATION (VO):

continue previous shot
HSM18A, tape 06, 06:04:55-06:05:05 THEY SHOULD BE POWERFUL,
zoom out, high speed machining
operation PROVIDE EXTREMELY HIGH SPINDLE SPEEDS AND
HSM18B, tape 14, 17:18:52-17:19:03
zoom out, dry machining ACCELERATION...,
HSM18C, tape 10, 11:58:14-11:58:25
tool storage, tools indexing BE EQUIPPED FOR NEAR OR COMPLETELY DRY
HSM18D, tape 02, 02:02:18-02:02:35
zoom out, parts on fixtures, MACHINING...,
indexing
HSM18E, tape 10, 11:45:30-11:45:55 OFFER OPTIONS SUCH AS ADDITIONAL TOOL STORAGE
part/fixture moving into machine
AND TOOL MONITORING...,

SUPPLEMENTARY PART FIXTURING...,

AND FAST PART DELIVERY AND REMOVAL.

SCENE 19. NARRATION (VO):

HSM19A, tape 02, 02:21:05-02:21:25
zoom in, controller to machining THE MACHINE CONTROL SYSTEM SHOULD BE FAST,
process
RESPONSIVE AND FLEXIBLE. IT SHOULD HAVE

INTERPOLATION CAPABILITIES,

SUB-PROGRAMS FOR COMPLEX PART MACHINING,

AND THE ABILITY TO TOTALLY INTEGRATE WITH

 Copyright © 2007 Society of Manufacturing Engineers

OTHER IN-HOUSE SYSTEMS.

SCENE 20. NARRATION (VO):

HSM20A, tape 14, 17:08:53-17:09:15
c.u., zoom out, spindle turning DIRECT CONNECTION OF THE MOTOR TO THE SPINDLE
tool, machining part
IS PREFERRED OVER THE USE OF BELTS AND GEAR

DRIVE TRAINS. BECAUSE THESE INTEGRAL SPINDLES

ARE COUPLED DIRECTLY TO THE MOTORS, THEY CAN

ACCELERATE AND DECELERATE FASTER THAN THE

DRIVE TRAIN SYSTEMS.

SCENE 21. NARRATION (VO):

HSM21A, CGS: Tooling
HSM21B, tape 06, 07:11:24-07:11:37 HIGH SPEED TOOLING MUST BE ABLE TO WITHSTAND
high speed machining emphasizing
tooling THE INCREASED SPINDLE SPEEDS, FEED RATES AND

HEAT BUILD-UP IN THE PROCESS.

SCENE 22. NARRATION (VO):

HSM22A, CGS: Hollow Shank Taper/HSK
HSM22B, tape 02, 02:04:38-02:04:48 HOLLOW SHANK TAPER OR ‘HSK’ TOOL HOLDERS WERE
zoom in, hsk tool holder
HSM22C, tape 14, 17:31:54-17:32:20 DEVELOPED FOR HIGH SPEED OPERATIONS AND ARE
zoom in, high speed machining using
hsk tool holder PREFERRED OVER CONVENTIONAL ‘CAT’ V-FLANGE OR

STEEP SHANK TOOL HOLDERS IN MANY APPLICATIONS.

SCENE 23. NARRATION (VO):

HSM23A, tape 14, 17:02:46-17:03:29
zoom out, high speed machining HOLLOW SHANK TAPER TOOL HOLDERS OFFER THE
operation using hsk tool holder
HSM23B, CGS: High Torque ADVANTAGES OF:
Transmission
High Repeatability HIGH TORQUE TRANSMISSION,
Accuracy
Excellent Adaptation to HIGH REPEATABILITY ACCURACY,
High Speed Cutting
Uniformity EXCELLENT ADAPTATION TO HIGH SPEED CUTTING,
Minimal Runout
High Clamping Force UNIFORMITY,
Reliability & Safety
Static & Dynamic MINIMAL RUNOUT,
Stiffness
HIGH CLAMPING FORCE,

RELIABILITY AND SAFETY,

 Copyright © 2007 Society of Manufacturing Engineers

AND STATIC AND DYNAMIC STIFFNESS.

SCENE 24. NARRATION (VO):

HSM24A, tape 03, 03:19:55-03:20:06
zoom out, cutting tool clamped into HOW CUTTING TOOLS ARE CLAMPED INTO THE TOOL
tool holder
HSM24B, tape 11, 13:34:34-13:34:50 HOLDERS IS ALSO VERY IMPORTANT. THE THREE
thermal clamped cutting tool placed
into tool holder PRIMARY CUTTING TOOL CLAMPING SYSTEMS USED FOR
HSM24C, CGS: Mechanical
Hydraulic HIGH SPEED MACHINING ARE:
Thermal
MECHANICAL,

HYDRAULIC,

AND THERMAL.

SCENE 25. NARRATION (VO):

HSM25A, tape 05, 05:52:50-05:53:10
high speed machining operation THE SUCCESS OF ANY CUTTING OPERATION IS
HSM25B, tape 06, 07:05:50-07:05:59
zoom out, cutting tool with ceramic DETERMINED BY WHAT HAPPENS AT THE POINT OF
inserts
HSM25C, tape 06, 07:10:13-07:10:32 CONTACT BETWEEN WORKPIECE AND CUTTING TOOL.
zoom out, cutting tools
THERE ARE A VARIETY OF CUTTING TOOL MATERIALS,

BOTH COATED AND UNCOATED, AND CUTTING TOOL

GEOMETRIES USED THAT OFFER BETTER-THAN-AVERAGE

TOUGHNESS AND GOOD HEAT RESISTANCE FOR HIGH

SPEED OPERATIONS.

SCENE 26. NARRATION (VO):

HSM26A, CGS: Programming/Software
HSM26B, tape 681, 08:09:22-08:09:50 AN INITIAL PITFALL COMPANIES FACE WHEN FIRST
use of conventional machining
software USING HIGH SPEED MACHINING IS ATTEMPTING TO

RE-USE CONVENTIONAL PROGRAMMING AND SOFTWARE.

SCENE 27. NARRATION (VO):

HSM27A, tape 01, 01:45:26-01:45:50
zoom out, esprit software being used USING SOFTWARE INTENDED SPECIFICALLY FOR HIGH
HSM27B, outgoing music, up and under
SPEED MACHINING OPERATIONS WILL YIELD SUPERIOR

QUALITY AND CONSISTENT, OPTIMIZED RESULTS.

SCENE 28. NARRATION (VO):

continue music
 Copyright © 2007 Society of Manufacturing Engineers
HSM28A, tape 14, 17:01:18-17:01:32
worker using controller
SCENE 29.
HSM29A, CGS: Trutron Corporation
HSM29B, MI background
HSM29C, tape 02, 02:09:10-02:09:36
zoom in, high speed machining
SCENE 30.
HSM30A, tape 01, 01:03:59-01:04:47
tim griswold on camera
/remove section/
HSM30B, CGS: Timothy J. Griswold
Vice President of
Manufacturing
Trutron Corporation
HSM30C, tape 02, 02:16:58-02:17:15
zoom out, high speed machining of
part
SCENE 31.
HSM31A, tape 14, 17:43:02-17:43:15
zoom out, trutron edming
HSM31B,still, constant-velocity
joint tooling
HSM31C,still, fluid-powered pump
parts
HSM31D, tape 02, 02:10:57-02:11:06
zoom out, high speed machining
operations
ALSO, EXTENSIVE TRAINING IS ESSENTIAL FOR ALL
EMPLOYEES INVOLVED, SO THAT THEY BECOME
COMFORTABLE WORKING WITHIN THE PARAMETERS OF
HIGH SPEED MACHINING.
--- TOUCH BLACK ---
NARRATION (VO):
THE TRUTRON CORPORATION IN TROY, MICHIGAN
BEGAN USING HIGH SPEED MACHINING IN THE LATE
90’S. WHAT INITIALLY PEAKED TRUTRON'S INTEREST
IN HIGH SPEED MACHINING WAS THE TIME SAVINGS
THE NEW MACHINERY COULD POTENTIALLY BRING
THEM.
GRISWOLD, ON CAMERA:
What we were looking for in the high-speed
machining arena was really twofold for our
company. We do a lot of sinker EDM work here,
so the creation of graphite electrodes and
copper electrodes takes a lot of time. We were
looking for a piece of equipment that could
aid in that and eliminate a job position per
se, utilizing that person somewhere else in
the company, but not consuming so much of
their time. One side of it was the creation of
electrodes. The other side was machining
hardened steels or non-graphite products that
would allow us to streamline our processes and
increase our throughput by maintaining
consistencies in our part quality.
NARRATION (VO):
IN ADDITION TO OFFERING ELECTRICAL DISCHARGE
MACHINING SERVICES, TRUTRON CORPORATION
EXPANDED IT’S OPERATIONS TO PRODUCE CONSTANT-
VELOCITY JOINT TOOLING AND FLUID-POWERED PUMP
PARTS. THIS TYPE OF MACHINING REQUIRED GREAT
PRECISION TO PRODUCE A FINAL PRODUCT.
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 32.
HSM32A, tape 01, 01:05:21-01:06:07
tim griswold on camera
/remove section/
HSM32B, tape 14, 17:13:58-17:14:17
high speed machining operation
SCENE 33.
HSM33A, tape 01, 01:07:35-01:08:07
tim griswold on camera
HSM33B, tape 02, 02:12:50-02:13:10
high speed machining operation
SCENE 34.
HSM34A, tape 14, 17:35:30-17:35:57
zoom in, esprit software being used
HSM34B, tape 01, 01:19:17-01:20:07
mark cohrs on camera
HSM34C, CGS: Mark Cohrs
Engineering Manager
Trutron Corporation
SCENE 35.
continue previous shot
HSM35A, tape 01, 01:48:04-01:48:26
zoom in, nc code
HSM35B, tape 01, 01:42:03-01:42:54
zoom in, esprit software being used
to create tool path
GRISWOLD, ON CAMERA:
There is a skill set people have in this
business, and it’s very important when you
have a niche business that you maintain those
skill sets. It’s difficult to train people in
very precise, close tolerance work, and the
type of / high speed machining we were looking
for was very high quality, precision
machinery.
GRISWOLD, ON CAMERA:
The high speed machines work on heat treated
materials up to 64 Rockwell. We cut very thin
features, deep features. Moving into this
arena allowed us to eliminate OD grinding
operations, jig grinding operations. Things
that we would normally have 8, 10, 12
additional sequences in are now done in one or
two operations on the high speed machining
side. It has really been able to streamline
our process.
NARRATION (VO):
PART OF STREAMLINING TRUTRON’S HIGH SPEED
MACHINING PROCESS REQUIRED CHANGING TO
SOFTWARE DESIGNED SPECIFICALLY FOR HIGH SPEED
MACHINING. TRUTRON SELECTED ESPRIT SOFTWARE to
CREATE high speed TOOL PATHS BECAUSE IT WAS
FLEXIBLE ENOUGH TO MEET ALL OF THEIR NEEDS.
engineering manager, MARK COHRS explains their
process...
COHRS, ON CAMERA:
The programming process consists of creating a
solid model if I don’t receive one from the
customer. If I don’t, I usually receive a 2D
print, and I have to recreate the solid model
inside of Solid Works. From there I’ll read
the solid model into Esprit and create the
cutter path. There are multiple operations
inside the cutter path, depending on the
complexity of the part, multiple tooling,
multiple settings as far as feeds and speeds
and stopovers. After the cutter path is
created, depending on which machine I’ll be
sending it out to, that will be the particular
post I’ll use. At that point I’ll post out the
NC file and send it out to the machine.
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 36.
HSM36A, tape 01, 01:51:07-01:51:43
joe adamski on camera
HSM36B, CGS: Joseph Adamski
High Speed Machinist
Trutron Corporation
HSM36C, tape 02, 02:06:29-02:06:59
joe adamski programming at machine
controller
SCENE 37.
HSM37A, tape 14, 17:31:20-17:31:33
zoom out, high speed machining
operation
HSM37B, tape 01, 01:55:27-01:56:24
joe adamski on camera
SCENE 38.
continue previous shot
HSM38A, tape 02, 02:23:40-02:24:02
zoom out, high speed machining of
graphite
SCENE 39.
HSM39A, tape 02, 02:20:21-02:20:36
high speed machining operation
SCENE 40.
HSM40A, tape 01, 01:57:32-01:58:22
zoom in, joe adamski on camera
HSM40B, outgoing music, up and under
ADAMSKI, ON CAMERA:
When I get the part program sent out to the
machine from Mark, what I would first do is
run a graphics on it. I would edit the program
beginning and end, so the lead out and lead in
is correct, edit any M codes for coolant, tool
changes, oil air mist. If the part was run on
an angle and we had to transfer the coordinate
system, I would put that into the program,
letting the machine know what position the
part is in before it actually runs, and it
would skew the coordinate system accordingly.
NARRATION (VO):
TRUTRON CORPORATION USES ‘HSK’ TOOL HOLDERS IN
THEIR HIGH SPEED MACHINING OPERATIONS. JOE
ADAMSKI EXPLAINS IT’S BENEFITS.
ADAMSKI, ON CAMERA:
What we use here is an HSK tool holder. What
you’re looking at is a 40E. This is meant for
high speed machining, it is balanced to 42,000
rpm. The nice thing about this is, it has a
very short taper, it has a hollow end shank.
When you put this into the machine, the
grippers will actually come in, grab the tool
holder by the inside and pull it back up into
the spindle, creating a very, very rigid tool
holder. It’s supposed to be two times more
rigid than a cat style holder. You can
increase your depth of cut, your rpms, your
feed and speed, all without sacrificing any
rigidity or part tolerance.
NARRATION (VO):
OVER TIME, TRUTRON HAS FOUND THAT THE KEY
ELEMENT TO MAKING A SUCCESSFUL TRANSITION TO
HIGH SPEED MACHINING IS BEING OPEN TO CHANGE
IN ALL AREAS.
ADAMSKI, ON CAMERA:
...you have to pretty much throw out the
rulebook of conventional milling. You have to
take a look at your tool holders, your end
mills, the part that you’re machining, how
rigid is your setup, what style NC code are
you using. Are you using conventional style
milling, climb milling, are you constantly on
the part. There are so many different things
 Copyright © 2007 Society of Manufacturing Engineers

to look at, don’t be afraid to experiment,

don’t get frustrated, don’t be afraid to try.
The guidelines you get from cutting tool
manufacturers is only a place to start.
They’re not using the same tool holder as you,
the same machine, NC code, material. It’s a
good place to start, but you can always
improve, and just keep trying.

--- TOUCH BLACK ---

SCENE 41. NARRATION (VO):

HSM41A, CGS: Protomatic Inc.
HSM41B, MI background PROTOMATIC INCORPORATED, BASED IN DEXTER,
HSM41C, tape 05, 05:34:30-05:34:44
zoom out, machinist working at MICHIGAN, IS A HIGH-QUALITY PROTOTYPE AND
machining center
HSM41D, tape 08, 09:02:09-09:02:21 SHORT-RUN PRODUCTION MACHINING OPERATION.
high speed machining operation
HSM41E, tape 04, 04:42:10-04:42:41 PROTOMATIC WAS INTERESTED IN HIGH SPEED
doug Wetzel on camera
HSM41F, CGS: Doug Wetzel MACHINING FOR PRICE POINT AND PERFORMANCE, AS
Vice President &
General Manager DOUG WETZEL, VICE PRESIDENT AND GENERAL
Protomatic Inc.
MANAGER POINTS OUT.

SCENE 42. WETZEL, ON CAMERA:

continue previous shot ...In a more competitive market, you need to
be a little more aggressive on your pricing.
Therefore, we were enticed into looking for
new avenues to improve our efficiency.

SCENE 43. NARRATION (VO):

HSM43A, tape 15, 18:03:36-18:04:00
high speed machining operation IN BUSINESS FOR OVER THIRTY YEARS, PROTOMATIC

OFFERS IN-HOUSE DESIGN SERVICES AND PROTOTYPE

MANUFACTURING TO CLIENTS IN THE AUTOMOTIVE,

ELECTRONIC, MEDICAL AND OPTICAL FIELDS.

SCENE 44. NARRATION (VO):

HSM44A, tape 05, 05:50:48-05:51:10
wide, high speed machining operation WHILE PROTOMATIC HAS OFFICIALLY BEEN USING

HIGH SPEED MACHINING FOR THE PAST THREE YEARS,

THE TRANSITION TO IT WAS A NATURAL EVOLUTION.

SCENE 45. WETZEL, ON CAMERA:

HSM45A, tape 04, 05:00:27-05:00:59 ...I think we’ve been high speed machining
doug Wetzel on camera much earlier than that we just didn’t know it,
HSM45B, tape 15, 18:18:27-18:19:10 and we always pushed our technology to the
zoom out, high speed machining limit. When you have a 10,000 or 12,000 rpm
 Copyright © 2007 Society of Manufacturing Engineers
operation
SCENE 46.
HSM46A, tape 08, 09:01:22-09:01:44
setting up and running high speed
machining operation
SCENE 47.
HSM47A, tape 04, 04:49:00-04:49:49
doug Wetzel on camera
HSM47B, tape 459, 04:26:57-04:27:30
investment casting operation
HSM47C, tape 451, 18:24:17-18:24:58
permanent mold casting
SCENE 48.
HSM48A, tape 03, 03:36:16-03:36:28
zoom out, high speed machining
operation with a lot of coolant
SCENE 49.
HSM49A, tape 03, 03:29:32-03:30:10
protomatic employee working with d3
vibrations
HSM49B, tape 08, 09:30:25-09:30:53
zoom out, protomatic employee
working with machining efficiencies
SCENE 50.
HSM50A, tape 04, 04:15:39-04:17:00
david dilley on camera
HSM50B, CGS: David Dilley, D.Sc.
Owner
D3 Vibrations Inc.
HSM50C, tape 03, 03:31:00-03:31:25
zoom out, listening to process with
microphone
machine, you’re going to of course push it to
the max. The carbide can take it, the machines
can take it, and of course, the parts are
manufactured quicker with that technique.
NARRATION (VO):
THE CONVERSION FROM CONVENTIONAL MACHINING TO
HIGH SPEED MACHINING HAS HELPED PROTOMATIC TO
MAINTAIN AND THEN SUBSEQUENTLY GAIN MARKET
SHARE IN SEVERAL AREAS OF BUSINESS.
WETZEL, ON CAMERA:
...The most prevalent is applications where
people need low weight, high strength
applications, where castings cannot create the
strength that a billet would. The other
application is simply trying to penetrate into
the casting world. We have many applications
where they would have typically been done with
lost wax or permanent die type of casting, and
we simply machine them from billet. It’s more
cost effective to do that in low quantities.
NARRATION (VO):
THE USE OF HIGH SPEED MACHINING ALSO MAGNIFIED
COMMON MACHINING PROBLEMS, SUCH AS EXCESSIVE
CHATTER AND VIBRATION, AND COOLANT ISSUES.
NARRATION (VO):
TO ADDRESS THESE PROBLEMS, PROTOMATIC SOUGHT
THE HELP OF D-3 VIBRATIONS AND MACHINING
EFFICIENCIES. BOTH COMPANIES ARE CONSULTANTS
WHO SPECIALIZE IN ACHIEVING OPTIMUM
PERFORMANCE FROM HIGH SPEED MACHINES.
DILLEY, ON CAMERA:
When I first approach a problem, I listen to
it acoustically. I want to see what is going
on in their process. When we listen to it
acoustically and we get the parameters that
they’re running, the rpm’s, number of teeth,
things like that, we can look at it and see is
there chatter present or is there not. Most
people can tell if there’s chatter or not,
 Copyright © 2007 Society of Manufacturing Engineers
HSM50D, tape 03, 03:07:04-03:07:26
zoom in, hammer and accelerometer
used on tool
HSM50E, tape 03, 03:08:45-03:09:18
acoustic reading of tool/hammer
HSM50F, tape 03, 03:09:22-03:09:42
stability diagram of from tool stack
up
SCENE 51.
HSM51A, tape 03, 03:28:10-03:28:29
zoom out, stability diagram
SCENE 52.
HSM52A, tape 04, 04:27:34-04:28:48
david dilley on camera
HSM52B, stability diagram 01
HSM52C, stability diagram 02
HSM52D, tape 05, 05:12:32-05:13:18
high speed machining
HSM52E, stability diagram 03
SCENE 53.
HSM53A, tape 15, 18:13:26-18:13:50
zoom out, high speed machining
operation
HSM53B, tape 08, 09:27:30-09:28:00
gary speaking with doug
that’s not the great idea of the technology.
But if it is chattering, we know what
frequencies are chattering, and we can go
after those. Our acoustic method, we can many
times fix a problem just using our acoustic
method, if it is chattering. Our technology
tells us exactly what rpm to try to find that
sweet spot. If that fails, or we want to go to
the next step, we use the hammer and
accelerometer technique, called modal
analysis. Modal analysis is nothing special to
myself and my colleagues, they use it in many
industries. But we use it differently than
other vibration companies might do. We get
that fingerprint of the tool stack-up, so we
know what the tool is in the given system.
Then we take the tests and we make a stability
diagram.
NARRATION (VO):
THE STABILITY DIAGRAM NOT ONLY PROVIDES
INFORMATION REGARDING THE IDEAL SPEEDS AND
DEPTH OF CUTS FOR CHATTER FREE MACHINING, BUT
ALSO A WINDOW INTO THE REGIONS OF THE
MACHINING PROCESS THAT ARE PROBLEMATIC.
DILLEY, ON CAMERA:
There’s this region, which I call the Poor Man
Region, which is the area we really don’t want
to run into. The red area is chattering. You
can see there’s no real good white spots to
run, which is where it’s stable. So almost
anywhere running those depths of cuts and
those spindle speeds, you’re going to have a
chatter problem, and consistently won’t be
able to run there. We try to get people into
what we call the High Performance Region. The
High Performance Region is right above the
High Speed Region, and we can see there are
areas that you can get high depths of cuts
when you choose the correct spindle speed.
This is kind of like adding stiffness into
your system. By choosing the right rpm, you
can oftentimes make your tool act like it’s
three or four times stiffer than it really is.
NARRATION (VO):
ONCE D-3 VIBRATIONS IDENTIFIED THE OPTIMUM
SPEED, DEPTH OF CUT, AND FEED REGIONS FOR
 Copyright © 2007 Society of Manufacturing Engineers

PROTOMATIC’S HIGH SPEED MACHINING OPERATIONS,

MACHINING EFFICIENCIES CAME IN TO EXAMINE

THEIR ENTIRE MACHINING PROCESS.

SCENE 54. RODAK, ON CAMERA:

HSM54A, tape 04, 04:32:20-04:32:44
gary rodak on camera
/remove section/
HSM54B, CGS: Gary Rodak, CMfgE
President
Machining Efficiencies,
Inc.
...The first thing I do is look at the end
result of the cutting tool and the work piece.
We then take a look at the stability of the
structure of the fixture, the flooding
techniques, the quality of the coolant,
cleanliness of the coolant, pretty much a
checklist of nine elements that go into making
a good part.

SCENE 55. NARRATION (VO):

HSM55A, tape 08, 09:15:27-09:16:07
zoom out, high speed machining THIS CHECKLIST OF NINE ELEMENTS INCLUDES:
operation
HSM55B, CGS: Part & Process Design THE PART AND PROCESS DESIGN,
Part Material &
Hardness THE PART MATERIAL & HARDNESS,
Blank Manufacturing
Quality THE BLANK MANUFACTURING QUALITY,
Tool Design &
Manufacture THE TOOL DESIGN & MANUFACTURE,
Fixture Design &
Manufacture THE FIXTURE DESIGN & MANUFACTURE,
Machine Condition
Gages & Technique Used THE MACHINE CONDITION INCLUDING FILTRATION,
Lubricant Chemistry,
Condition & THE GAGES & TECHNIQUE USED,
Application
Machine Operator THE LUBRICANT CHEMISTRY, CONDITION &

APPLICATION,

AND THE MACHINE OPERATOR.

SCENE 56. RODAK, ON CAMERA:

HSM56A, tape 04, 04:40:22-04:40:55
gary rodak on camera
/remove section/
HSM56B, tape 03, 03:40:40-03:41:11
zoom out, plant floor wear pattern
demonstrating chatter
HSM56C, scroll of 11 wear patterns
HSM56D,wear pattern image 01
HSM56F,wear pattern image 03
What was interesting about this particular
investigation we did is that the wear patterns
on the cutting edges was very evident of being
a chipping type wear pattern. There are
essentially 11 types of wear patterns that are
fairly clear, with fairly unique causes and
cures. In this case this was a classic type
wear pattern that you see on a cutting edge
that you use with a chatter condition.

SCENE 57. NARRATION (VO):

HSM57A, tape 05, 05:50:30-05:50:45
zoom in, high speed machining IT WAS DETERMINED THAT ADJUSTMENTS IN
operation with a lot of coolant
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 58.
HSM58A, tape 04, 04:38:55-04:39:55
gary rodak on camera
HSM58B, tape 08, 09:19:00-09:20:00
zoom in, high speed machining
operation with a lot of coolant
HSM58C, tape 03, 03:05:00-03:05:17
tilt, coolant filtration unit
SCENE 59.
HSM60A, tape 08, 09:14:50-09:15:19
setting up and high speed machining
operation
SCENE 60.
HSM61A, tape 04, 04:58:47-04:59:45
doug wetzel on camera
/remove section/
HSM61B, tape 03, 03:26:18-03:26:38
worker at controller working with
david dilley
HSM61C, outgoing music, up and under
PROTOMATIC’S COOLANT CHEMISTRY AND IT’S
FILTRATION WERE NEEDED TO STABILIZE THEIR HIGH
SPEED MACHINING OPERATIONS. GARY RODAK
EXPLAINS.
RODAK, ON CAMERA:
When you’re moving from low speed or
conventional type machining speeds to high
speed, the metalworking fluid is much more
critical. Flood rates have to be proper,
cleanliness is critical, and so is
concentration. At slow speeds, it’s still very
important, and sometimes it’s overlooked,
because it’s one of those messy chemical
things and it’s oily and so on, and people
don’t like to mess with that. But especially
for high speed, you need to have good aim for
your fluid, you need to have very clean fluid.
When you’re working with a spindle that’s
working at 15,000 or 20,000 rpm, small
sediment lodges in areas that actually destroy
the internal workings of that spindle. You can
wear out your pumps very quickly. It’s not the
20 micron particles that are easy to filter
that cause the problem; it’s the small 1- to
5-micron range that creates most of the
problem.
NARRATION (VO):
AS WITH ANY TECHNOLOGY, HIGH SPEED MACHINING
OFFERS AN OPPORTUNITY TO LEARN NEW APPROACHES
TO MANUFACTURING. IN PROTOMATIC’S CASE THE
LESSONS LEARNED WERE TWO FOLD.
WETZEL, ON CAMERA:
One is the selection of the right type of
equipment, and that goes for coolant and
tooling and tool holders. The other large
element is the personal side, and that’s
properly most significant, is the proper
training for the personnel. Personnel has to
have the right tools to understand what has to
be done next. We are moving into a territory
that is not intuitive, it is an area that you
need tools to understand and to make
corrections from your feed, your speed, your
rpm and depth of cut, and those are critical
in the decision making process.
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 61.
HSM62A, CGS: Gosiger 3D
HSM62B, MI background
HSM62C, tape 06, 06:11:24-06:11:44
zoom out, high speed machining
SCENE 62.
HSM63A, tape 06, 07:04:02-07:04:14
zoom out, high speed machining
operation
HSM63B, tape 06, 07:11:53-07:12:10
zoom out, hard milling operation
SCENE 63.
HSM64A, tape 06, 07:19:35-07:19:59
high speed machining operation
HSM64B, tape 07, 08:39:07-08:39:55
dale mickelson on camera
HSM64C, CGS: Dale Mickelson
President
Gosiger 3D
SCENE 64.
continue previous shot
SCENE 65.
HSM66A, tape 06, 07:21:23-07:21:42
zoom out, hard milling operation
--- TOUCH BLACK ---
NARRATION (VO):
HELPING MANUFACTURERS TO REFINE THEIR HIGH
PERFORMANCE MACHINING OPERATIONS IS THE GOAL
OF PLYMOUTH, MICHIGAN BASED GOSIGER-3D.
NARRATION (VO):
THE FACILITY DEVELOPS AND TESTS BOTH HIGH
SPEED AND HARD MILLING MACHINING SYSTEMS,
OFFERING CUSTOMERS A FULL-LINE OF MACHINE
RELATED SERVICES ALONG WITH THE NECESSARY
TECHNICAL SUPPORT.
NARRATION (VO):
HIGH SPEED AND HARD MILLING OPERATIONS ARE
SIMILAR IN TECHNIQUE, BUT THEIR DIFFERENCES
ARE DISTINCT. DALE MICKELSON ELABORATES...
MICKELSON, ON CAMERA:
The way we define high speed machining to hard
milling is, high speed machining is the pre-
rough or the roughing of the material before
heat-treating. Or if it’s an aluminum or a
material that doesn’t get heat treated, and
you actually have a finished product when
you’re done, there’s no after process, then
high speed machining would do the finishing.
Hard milling is where we put the accuracy and
finish into the part after heat treating. In
that case, we’re replacing in some cases EDM,
EDM electrode, EDM wire, and also hand
polishing and jig grinding.
NARRATION (VO):
HARD MILLING, LIKE HIGH SPEED MACHINING CAN
PRODUCE PARTS QUICKLY, OFTEN WITH LITTLE OR NO
POST-MACHINING WORK REQUIRED. BUT COMPANIES
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 66.
HSM67A, tape 07, 08:35:00-08:35:33
dale mickelson on camera
SCENE 67.
HSM68A, tape 06, 07:12:18-07:12:36
wide, hard milling operation
HSM68B, tape 06, 07:11:06-07:11:13
zoom out, hard mill tooling
HSM68C, tape 13, 16:25:11-16:25:25
zoom out, hard milling software
SCENE 68.
HSM69A, tape 07, 08:09:53-08:10:23
dale mickelson on camera
HSM69B, tape 06, 07:21:48-07:22:16
zoom in, hard milling operation
HSM69C, tape 06, 07:16:31-07:16:46
wide, hard milling operation
SCENE 69.
HSM70A, tape 07, 08:18:47-08:20:01
dale mickelson on camera
HSM70G, tape 06, 06:21:01-06:21:24
zoom out, high speed machining
operation
SCENE 70.
HSM71A, tape 07, 08:13:31-08:13:54
dale mickelson on camera
HSM71B, tape 13, 16:08:10-16:08:30
zoom out, high speed machining
software being used
HSM71C, tape 13, 16:02:10-16:02:20
zoom out, part
SCENE 71.
HSM72A, tape 13, 16:23:30-16:23:57
software using trochoidal
interpolation
ARE OFTEN SKEPTICAL ABOUT THESE CLAIMS.
MICKELSON, ON CAMERA:
...We get into companies that can’t believe we
can make their part in 18 minute when they’re
making it in 2 hours. We go in and it really
takes the customer to understand by seeing.
They have to see the process, and see their
parts being made in this process.
NARRATION (VO):
AS WITH HIGH SPEED MACHINING, HARD MILLING
REQUIRES LOOKING AT THE MACHINE TOOL, TOOLING
AND SOFTWARE AS INTEGRAL COMPONENTS TO ACHIEVE
OPTIMUM RESULTS.
MICKELSON, ON CAMERA:
The base of the hard milling process is the
machine. So there are certain machines we look
at for doing this process, and they’re rigid
and accurate. The next part of the process is
the holders. If they have conventional style
holders or conventional style setups, and they
try to go into hard milling, it gets pretty
hard for them. A lot of companies actually try
hard milling that way and don’t succeed at it,
and they give up on it.
MICKELSON, ON CAMERA:
We use a certain holder for the application,
the hard milling and high speed machining.
We’re looking for holders that are rigid and
terrific TIR’s and actually have dampening
effect, holders like that.
MICKELSON, ON CAMERA:
The software that I would recommend are
softwares that are made for hard milling in
high speed machining. We’re looking for
something that will put out good finishes,
have arc-in and arc-out ability, so it flows
into the material slowly and smoothly. The
ability to basically put out a good finish is
our biggest goal on that software.
NARRATION (VO):
THE SOFTWARES MOST BENEFICIAL FOR HARDMILLING
AND HIGH SPEED MACHINING OPERATIONS CREATE
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 72.
HSM73A, tape 13, 16:27:53-16:28:23
software using trochoidal
interpolation
HSM73B, tape 07, 08:16:28-08:16:54
dale mickelson on camera
SCENE 73.
HSM74A, tape 13, 16:32:15-16:32:40
software using trochoidal
interpolation
HSM74B, tape 07, 08:15:16-08:16:01
dale mickelson on camera
SCENE 74.
HSM75A, tape 13, 16:25:25-16:25:40
software using stock recognition
SCENE 75.
HSM76A, tape 07, 08:16:02-08:16:22
dale mickelson on camera
SCENE 76.
HSM77A, tape 06, 07:14:36-07:14:55
zoom out, hard milling machining
operation
SCENE 77.
HSM78A, tape 07, 08:32:55-08:33:39
dale mickelson on camera
TOOL PATHS USING A TECHNIQUE CALLED
TROCHOIDAL.
MICKELSON, ON CAMERA:
Trochoidal is basically circular interpolating
through a slot. A slot would be a linear move
straight through it. Trochoidal gives it the
ability to actually profile a cut through a
slot. Slotting would actually push the
material through. The end mill would be
pushing the material and creating extreme
heat. The end mills today for hard milling are
actually made for profiling, not slotting.
MICKELSON, ON CAMERA:
...When trochoidal first came out, I tested it
to see how good it was compared to slotting,
if it was really a positive, because of the
extended cycle time it would create. In the
tests I found there was actually nine times
more tool life by using trochoidal slotting.
So we look for softwares that have trochoidal
built into it, and something where a software
would only put trochoidal where it needed to,
not for the whole part. We don’t want the
extra tool path....
NARRATION (VO):
ANOTHER SOFTWARE FEATURE THAT ASSISTS IN
OPTIMIZING THE MACHINING PROCESS IS STOCK
RECOGNITION.
MICKELSON, ON CAMERA:
...as we go in with a large cutter and remove
a lot of the material, we are looking for the
next cutter, maybe another roughing cutter, to
actually go in and recognize where the
material has been removed and only do the work
it needs to, thus eliminating air cut. That’s
another thing we need in our softwares.
NARRATION (VO):
HARDMILLING CAN REDUCE TIME AND IMPROVE
QUALITY, BUT IT HAS ITS LIMITATIONS.
MICKELSON, ON CAMERA:
Some of the limitations to hard milling are
some of the materials we get into. If they’re
over 70 Rockwell, the cutter technology just
isn’t there in some cases. Basically the
 Copyright © 2007 Society of Manufacturing Engineers
SCENE 78.
HSM79A, tape 06, 07:18:20-07:18:36
hard milling machining operation
SCENE 79.
HSM80A, tape 07, 08:37:01-08:37:45
dale mickelson on camera
HSM80B, outgoing music, up and under
SCENE 80.
HSM81A, CGS: Metlfab Incorporated
HSM81B, MI background
HSM81C, tape 09, 10:02:05-10:02:23
zoom in, high speed machining
operation
HSM81D, tape 09, 10:02:39-10:02:51
zoom in, high speed machining
operation
HSM81E, tape 12, 15:03:30-15:04:20
don swart on camera
HSM81F, CGS: Don Swart
Machine Shop Manager
Metlfab, Incorporated
SCENE 81.
continue previous shot
HSM82A, tape 09, 10:13:45-10:14:09
high speed machined part pulled from
machine
HSM82B, tape 10, 11:55:06-11:55:15
coating won’t hold up. Then it’s just not
feasible to hard mill. When your cutters, you
maybe get 5 or 10 minutes of tool life in
material over 70 Rockwell. In some cases
length is an issue for us. If it’s a straight
wall and it’s more than 10 to 1 length to
diameter ratio, we generally don’t want to
work with that. That’s where EDM would come in
and work for the customer.
NARRATION (VO):
WHEN IT IS AN APPROPRIATE MANUFACTURING
OPTION, HARDMILLING CAN SAVE TIME, MONEY AND
IMPROVED QUALITY.
MICKELSON, ON CAMERA:
There was a case study we did. The customer is
doing the part in 30 hours, using conventional
EDM and hand finishing, and basic machining,
prepping the part. They would make the
electrode they made actually 3 electrodes.
Then they polished the three electrodes so
they didn’t have any machining marks in it.
Then they would EDM the part, and when the
whole process got done, they would polish the
part. What we did is went in and actually made
the part. It was S7 60 58 Rockwell. We made
the parts in 2.5 hours for the customer using
hardmilling.
--- TOUCH BLACK ---
NARRATION (VO):
WHEN METLFAB INCORPORATED, A JOB-SHOP IN
FREDERICK, MARYLAND, BEGAN PURCHASING HIGH
SPEED MACHINING CENTERS, THE MAIN ATTRACTION
WAS PRODUCTION SPEED. WITH APPROXIMATELY ONE-
HUNDRED CUSTOMERS, METLFAB’S SPECIALTY IS
LIMITED PRODUCTION OF PROTOTYPES WITH A QUICK
TURNAROUND TIME. DON SWART EXPLAINS...
SWART, ON CAMERA:
...What we found out was that so much of the
work today is being sent overseas for
production. Plain and simply, we can’t compete
in that market. So we decided to take on the
prototype, quick turnaround stuff. As I put it
 Copyright © 2007 Society of Manufacturing Engineers
zoom out, parts
HSM82C, tape 10, 11:47:59-11:48:20
zoom out, part being gaged
SCENE 82.
HSM83A, tape 10, 11:11:24-11:11:58
high speed machining operation
HSM83B, zoom out, still cell tower
HSM83C, tape 10, 11:07:30-11:07:52
zoom out, high speed machines on
shop floor
SCENE 83.
HSM84A, tape 11, 13:16:31-13:17:35
don swart on camera
SCENE 84.
HSM85A, tape 09, 10:09:51-10:10:26
zoom out, high speed machining
operation
SCENE 85.
HSM86A, tape 11, 13:47:20-13:48:00
travis shatzley on camera
HSM86B, CGS: Travis Shatzley
Programmer
Metlfab, Incorporated
HSM86C, tape 09, 10:03:07-10:03:24
zoom out, high speed machining
sometimes, a lot of companies are trying to
find the new mousetrap. Everybody is out
there, quickly give me five pieces, I need to
go test it, I need to find out if it will
work, if it works it will sell. There’s a big
market for that.
NARRATION (VO):
METLFAB’S FABRICATING AND FINISHING SERVICES
ARE USED IN A VARIETY OF HIGH-END
COMMUNICATION TECHNOLOGIES, SUCH AS CELL PHONE
TOWERS. AS A HABIT, METLFAB TYPICALLY SWITCHES
OUT THEIR MACHINES EVERY FIVE YEARS. SO WHEN
THE TIME CAME THEY LOOKED AT HIGH SPEED
MACHINING CENTERS.
SWART, ON CAMERA:
...I found everybody said they had high speed,
and it was just higher RPM. You really weren’t
gaining anything, because they didn’t have the
accelerations and decelerations. In many cases
these improvements, so they would be higher
RPM and a little bit faster feed rate, but you
were only gaining 10 or 15 percent in your
production. As we got into what our customer
needs are, I needed something that was going
to improve it at a much higher rate than
that...
NARRATION (VO):
AFTER DETERMINING THAT HIGH SPEED MACHINES
WOULD MEET THEIR PERFORMANCE NEEDS, METLFAB
FOUND THAT THEY ALSO REQUIRED A SIGNIFICANTLY
DIFFERENT APPROACH TO MACHINING THAN
CONVENTIONAL MILLING.
SHATZLEY, ON CAMERA:
...the main difference is depths of cuts and
widths of cuts. You can’t take the widths or
depths of cuts you used to, but you’re
machining so fast that the shallower depths of
cuts, or the less stepovers you have, you’re
machining so fast that it makes up for it. We
went from a quarter inch depth of cut to 125.
 Copyright © 2007 Society of Manufacturing Engineers
operation
SCENE 86.
HSM87A, tape 10, 12:04:27-12:04:40
zoom out, high speed machine tooling
SCENE 87.
HSM88A, tape 11, 13:48:37-13:49:52
travis shatzley on camera
HSM88B, tape 09, 10:01:36-10:01:52
zoom out, high speed machining
operation
HSM88C, tape 09, 10:03:24-10:04:01
zoom out, high speed machining
operation
SCENE 88.
HSM89A, tape 12, 15:36:51-15:37:09
zoom out, tool holders
SCENE 89.
HSM90A, tape 11, 13:54:47-13:56:15
travis shatzley on camera
/remove section/
HSM90B, tape 11, 13:37:32-13:37:54
But we’re running five times as fast feed rate
wise, ten times as fast feed rate wise. So
instead of cutting time in half, you’ve cut
time in four, even though you’re taking twice
as many cuts.
NARRATION (VO):
METLFAB ALSO CHANGED OVER ALL THEIR TOOLING TO
TAKE ADVANTAGE OF THE HIGH SPEED MACHINING
CENTERS.
SHATZLEY, ON CAMERA:
...We went from using standard end mills to
millimeter end mills, because instead of
jamming a quarter inch cutter into a corner to
get a 125 radius, we’re now rolling the corner
like you would on the side of a part. You can
actually mill right around the corner with
basically a smaller end mill. You get away
from the chatter in your corners that way. It
makes a lot smoother transition from one to
the other. The deceleration rate as you’re
coming from a straight line into a radius is
so… right now I believe it’s a 16th of an inch
is where it actually starts to slow down
before the transition, where before it used to
be a half inch. So you’re getting that extra
at 400 inches per minute, or however fast
you’re machining, into that corner before you
start in. As long as you roll the corner you
can keep the feed rate up. The feed rate,
instead of trying to transition from a
straight line to a radius, where before it
would slow down a half inch before it went to
a radius and it would ram into the corner. Now
it’s actually rolling at 450 inches the whole
way around the corner and back out. There is
no deceleration rate, because you have a
smaller radius.
NARRATION (VO):
TO ELIMINATE SOME CHATTER AND VIBRATION
ISSUES, METLFAB FOCUSED ON THE TYPE OF TOOL
HOLDERS THEY WERE USING.
SHATZLEY, ON CAMERA:
The chatter and vibration we got around by
going to solid heat shrink holders. Basically
you heat a holder up, you drop an end mill in,
and as it cools it shrinks the end mill right
 Copyright © 2007 Society of Manufacturing Engineers
zoom in, heating up tool holder, end
mill being dropped into holder
HSM90C, tape 11, 13:38:11-13:38:23
cooled end mill/tool holder removed
from machine
HSM90D, tape 09, 10:28:51-10:29:26
high speed machining operation
SCENE 90.
HSM91A, tape 09, 10:05:39-10:06:11
high speed machining operation
SCENE 91.
HSM92A, tape 12, 15:29:02-15:30:18
don swart on camera
/remove section/
HSM92B, tape 10, 11:42:00-11:42:20
zoom out, high speed machining
operation
SCENE 92.
HSM93A, tape 09, 10:15:52-10:16:06
wide, high speed machining
HSM93B, tape 12, 15:27:12-15:28:16
don swart on camera
SCENE 93.
continue previous shot
HSM94A, outgoing music, up and under
into the holder. There’s no more nuts, the
holders are all balanced. That’s an intricate
part of the whole thing is having balanced
holders. You can’t have a holder that’s
running out. That automatically causes your
chatter through harmonics. The chatter on the
sides of a part wasn’t a real big deal for us
before or after we changed. The biggest part
was in your corners, any corners you had in a
part. That’s where you end up running into
problems, because the radius on the end mill
is too close to the radius on the corner, and
it sucks the end mill in. The other part was
the tooling we used. We went to an end mill
that was a real high-density carbide
micrograin. They are a heavy end mill and they
will absorb a lot of shock...
NARRATION (VO):
METLFAB, ON SOME PROTOTYPES, CAN BOAST AN
EIGHT-HOUR TURNAROUND TIME. HOWEVER, BECAUSE
OF THE NATURE OF HIGH SPEED MACHINING, IT DOES
HAVE ITS LIMITATIONS.
SWART, ON CAMERA:
...High speed machining doesn’t work for all
applications. As much as we would like to see
it work, it does not work for everything. But
if you weigh how many it does work on against
how many it doesn’t work on, you far exceed
what you succeed on, and it becomes well worth
the investment.
NARRATION (VO):
FOR THOSE WHO ARE CONSIDERING HIGH SPEED
MACHINING EQUIPMENT, DON SWART OFFERS THIS
ADVICE...
SWART, ON CAMERA:
...don’t skimp on the quality, as far as the
machine you’re thinking of purchasing, the
tooling you’re thinking of using, the
programming you’re thinking of implementing,
you have to go with the top of everything.
There’s no use having a million-dollar piece
of equipment and putting $30 tool holders in
it. You need to have the best quality of
everything. Find out what fits your
application, but then go after the really good
 Copyright © 2007 Society of Manufacturing Engineers

stuff. It just stops headaches down the road.

--- TOUCH BLACK ---

SCENE 94. NARRATION (VO):

HSM95A, tape 14, 17:12:50-17:13:08
pan, worker to high speed machining WHETHER OR NOT TO INVEST IN HIGH SPEED
starting up
HSM95B, tape 06, 07:09:30-07:09:39 MACHINING EQUIPMENT, IS THE SAME, IT SEEMS, AS
zoom in, high speed tooling
HSM95C, tape 14, 17:33:32-17:33:47 ASKING WHETHER A COMPANY PLANS TO STAY
zoom out, high speed software
HSM95D, outgoing music, fade up with COMPETITIVE. WHILE A HIGH SPEED MACHINING
credits
CENTER IS A STARTING POINT, IT’S BY NO MEANS

COMPLETE UNLESS IT’S INTEGRATED WITH

APPROPRIATE TOOLING, SOFTWARE PROGRAMMING, AND

TRAINING.

SCENE 95. NARRATION (VO):

continue music
HSM96A, tape 09, 10:17:55-10:18:12 ADDITIONALLY, BY UNDERSTANDING YOUR PRODUCTION
parts fixtured for high speed
machining NEEDS AND ENLISTING THE ASSISTANCE OF
HSM96B, tape 10, 11:48:28-11:48:58
zoom out, high speed machining SUPPLIERS, THE GREATEST GAINS CAN BE GENERATED

WHEN MAKING THE TRANSITION TO HIGH SPEED

MACHINING.

--- TOUCH BLACK ---

SCENE 96. Manufacturing Insights wishes to thank the

HSM97A, CGS: credit roll
following contributors for their assistance in
white text, fade up mid-screen,
black to blue gradient background the production of this program:
D3 Vibrations Inc.
Gosiger 3D
Machining Efficiencies, Inc.
McCue & Associates
Metlfab, Incorporated
Mikron Bostomatic Corporation
Protomatic Inc.
Trutron Corporation
 Copyright © 2007 Society of Manufacturing Engineers

Produced By:
Society of Manufacturing Engineers

Executive Producer:
Steven R. Bollinger

Producer/Director/Cameraman/Editor:
Jerome T. Cook

Written By:
Kate Goodin

Portions Of This Program Were Excerpted

From The Book:
High-speed Machining
By Bert P. Erdel

Production Assistance Provided By:

Geoff Ernst
Lance A. Rosol

SCENE 97.
HSM98A, SME logo, with music