3D Prining is about to to take over traditional machining the same way CNC Machining took over manual machining.
Eventually 3D printing will replace casting too.

Since 3D Printing does not require complicated setup and programming, this in turn will lead to massive loss of machining-related jobs.

Read more to see if this is true!

Latest advances in tool technology make milling of high carbon and tool steels as reliable and predictable as benign aluminium alloys.

In this video a large 4140 steel component is being roughed out at 2700RPM and 600 inches per minute.
While achieving  impressive material removal rate (20 pounds of steel machined off in a matter of half an hour!) the tool life puts the old school square shoulder endmills to shame.

Yes, it could(and should) have been machined using a bigger cutter, but I wanted to put the tool to the test.
And it performed beautifully: Was able to surpass the recommended starting speeds and feeds by at least 170%!

There have been purely electric cars long before the Tesla Model 3.

But Tesla has made it cool. Sort of like how Apple made the iPhone cool, Tesla made not just gas-free, environment-saving cars. It made cool high-performance vehicles that are fun to drive.

And nobody really cares that Chevy Volt has already been available for years for a comparable price. Couple of days since its unveil, the new Model 3 has already outsold the Volt. Not a small feat, considering, they are only going to start delivering in about a year!

But Tesla, like Apple, like Amazon is in many ways a disruptive technology.

Most of email correspondence i receive is questions regarding use of my software, feature suggestions, material requests etc. Purely technical.

But sometimes i receive thank-you letters that make me feel all fuzzy and warm inside. It is a great feeling to know that something you do makes other people's work easier and more productive.

Yesterday I received a letter from one of HSMAdvisor's early users. He actually sent me a couple of short videos with a part he is currently making.

With his permission i am posting his letter:

Thank you Craig,

Over more than last two years you and many others have supported me with very valuable feedback and suggestions. Without all of you, it would have never come as far as it did.

And there is a lot more to come!

Manufacturing seems to be going back to North America, but thousands of college graduates who finish various CNC -related courses have a very shallow understanding of metal-cutting processes and forces involved.

Frankly i believe Speeds and Feeds should be a separate subject all together.

To help students fill the gap, I am offering US and Canadian educational facilities help with setting up their classes with free HSMAdvisor seats.

Update: Countries of EU and England are now included into the offer!

The total maximum number of seats handed out will be limited to 200.

If you represent a college or a university and want to sign up, please send me an email with your name, position, and number of seats requested.

My email address is cnc@zero-divide.net

I will set up your license and reply with information on how to obtain the license keys.

If you know a place that could benefit from this offer, please share this message.

Eldar Gerfanov, developer of HSMAdvisor and FSWizard machinists calculators.

HSM or High Speed Machining is becoming more and more popular each day.
Many of us have seen those youtube videos where endmlls remove large amounts of material at high speeds/feeds.

While definitions of HSM may vary between tool manufacturers and even individual shops, the physics behind it remain the same.

In this article i would like to explore flat endmills.

HSM is not about ramping up your speed/feed overrides to 200% and puling out your smartphone to record another youtube-worth video.

What is HSM?

HSM is a complex of programming, machining and tooling techniques aimed at radical increase of productivity.

Programming

The cornerstone of HSM is low radial and high axial engagement of an endmill with the workpiece.

There are many CAD/CAM systems that allow you to create HSM tool-paths. Mastercam's Dynamic milling and SurfCAM's Truemill are some of them.

When radial cutter engagement with the material is smaller than the radius of the tool an interesting thing happens.
Chip load- the distance the tool advances per cutter revolution per tooth- does not equal the actual chip thickness anymore.
Chip thinning mainly happens at radial engagements below 30% of the diameter.

In order to get compensated chipload you need to multiply recommended by manufacturer chipload by the chip thinning factor.

Usual Radial Engagement for HSM toolpaths however is between 5 and 15%.

Axial depth of cut varies depending on geometry, but

Radial Chip Thinning HSMAdvisor Screenshot