HSM Machining

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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%!Read More

Every month we are getting a good amount of feedback and suggestions.

Everything is getting prioritized and eventually implemented. Urgent stuff is getting done fast. And other "nice to haves" are getting pushed down according to their usefulness / difficulty (yes, everyone secretly wishes my program could also edit and create HSM g-code :)).

It is amazing, but almost half of HSMAdvisor's features were originally suggested by our loyal users!

The latest update HSMAdvisor 1.213 addresses some of the feedback I have received last couple of months.

So the New features are:

Smart Depth and Width of Cut (DOC/WOC) suggestion (user suggested)
Compressing of Shared Tool DataBases
Display of Stock status on Tool DataBase tables (user suggested)
Various little improvements like new Heli-Coil reference, better DOC/WOC calculation better multitasking, etc. (mostly based on user feedback)

Let's go over the most important ones here:

Before we run any G-Code program, we need to tell the machine where our part zero is.
A Part Zero is simply a bunch of numbers that offset the axis to give the machine a new coordinate point to work from.

Work Offsets is one of the most basic pieces of knowledge any machinist must-have.

Let us account for all the basic coordinate systems and definitions, available in a generic CNC machine

Machine Home and (Absolute) Machine Coordinates
Work Offset Coordinates
Tool Length Offsets

Machine Home and Machine Coordinates: G53

Machine Coordinates (or Absolute Coordinates) is the absolute and constant representation of the machine axis position.
These coordinates never change between Machine Restarts and must remain such. In fact, there is often no way for an operator to adjust the Absolute Machine Axis Home position.

Machine Home is simply that magical place where all Machine Coordinates should become Zero.

To Home the Machine is to start a machine operation, that will move all Axis to their soft limit position where X, Y, and Z-axis reading will be set to zero.

Homing must be done every time you restart your machine. Without it machine does not know where is the position of its table or spindle.

When homed your machine coordinates will read X=0 Y=0 and Z=0 and it is going to look like this:

The point where Machine X and Y intersect is called Table Home Position and the one where the Machine Z-axis starts from is called Spindle Home.

Now, there is no agreement between machine tool manufacturers on where the machine home should be.

As a developer of a very successful line of speed and feed calculators I sometimes get questions like : "I calculated speeds and feeds for a conventional toolpath. Got 5.5 cubic inches MRR(Material Removal Rate). And then I calculated S&F for the same endmill with HSM parameters turned on and got almost the same amount of MRR! What is even the point in using HSM parameters?" -they ask.

I would like to clear some things up for my friends.
In this article I will explain exactly WHY HSM machining is better and HOW to achieve better productivity and tool life.

For starters here are the main features of a HSM-capable cutter:

As usual there are several components of HSM that need to be present in order for it to work to its fullest. These are:

a) Machine
b) Tool
c) Workpiece geometry
d) Workpiece material

I intentionally did not number these as each one of those is equally important.

Added HSMAdvisor Cloud Services that allow users to Download and Upload their Machine Profiles.
You can now access your Machine Profiles from everywhere!
Users can also download each-other's Machine Profiles, uploaded as public.
Machine Power Curve Estimation wizard to help users map their Spindle Power Curve
Right-Click mouse click on selected rows launches a pop-up menu, that allows to insert and delete rows from the Power Curve table

The First Ever HSMAdvisor Speed and Feed Wizard hook for MasterCAM has been released today for everybody to download for free.

Getting it to this stage has been a titanic effort for me and I am going to put a lot more of it in the coming months: i need to get it to pretty much perfect state before i start forgetting how i did all those things.

Because of this each update i release will extend trial period by 30 days.

This will last for as long as needed to finish the bulk of developing it.

At this moment the following toolpaths are fully recognized:

Face Mill
Contour
Pocket
Drilling
Circle Mill
All 2D HST Toolpaths:
Dynamic Milling
Dynamic Area
Blend Mill
Peel Mill

The only exception is: Coolant parameters are getting lost somewhere in the process. So please double check it before posting!

Things to be added in the coming days/weeks/months:

Fix Coolant
Engraving
Other Circular Toolpaths such as ThreadMilling etc.
Conventional and HST 3D Toolpahs
Turning

If you have any suggestions or find any bugs please let me know.

I would like to reassure my current customers that HSMAdvisor Hook is/will be included with your license once this all is set and done.

Please help me with your suggestions/bug reports make this thing even better for all of you!

Here are the latest 2 videos i uploaded to my Youtube chanel

Setting up HSMAdvisor hook:

Calculating cutting parameters for Face Milling, Saving Tool and Cut data and recalling it when needed:

Cheers. And a huge "thank you" to everyone who has been supporting me!

New and updated features

New workpiece materials
Cutlery stainless steels have been added
Better scaling and control positioning on "Speeds and Feeds" page
Tool Database page now displays Libraries in multiple rows, which makes it easier to find stuff.
HSMAdvisor now installs by default into "Program Files (x86)" folder
It will still copy data files into your "AppDataRoamingHSMAdvisor" folder. So it will still pick up your old tool library and license file.
HSMAdvisor.ZIP archive now does not contain installer files, but rather ready-to use application folders, which you can unpack and use without installation.

As usual check our downloads page to get the update.

Now i know you are wondering when i will release updates to the mobile versions as well.
That should (hopefully) be done by this Monday.

Cheers!

I have just finished uploading the latest update for FSWizard apps to both iOS and Android stores.

Your iOS update should be available in about 3 to 5 days, while it is already available on Google Play.

As always my thanks go to Apple for killing 90% of my day on trying to find and fix stupid xCode quirks.
Thanks, apple guys! I wouldn't know what to do with all of my time if your stuff worked the way it was supposed to!

Here are just some of the changes in the latest version v1.40

Added new materials
Fixed Turning MRR/HP Calculation
Fixed Sticky Lead Angle
Changed WOC label in Turning mode to DOC

I have just uploaded my first FSWizard CNC MAchinists Speed and Feed Calculator video tutorial.

This is a quick walk through the basic functionality when using milling tools.

Please excuse my tired voice and occasional stuttering. This was my 9th take- every time either my computer crashed or i was interrupted by my kids running around and causing mess.

I am planning to release more videos. So please let me know what other topics i need to cover.

We have 2 new calculators available on Reference tab.
It is Oblique Triangle Calculator and a Fillet calculator.

I also fixed Floating Window's missing fields.

I have finally bought a proper microphone and was able to record a tutorial video, where i show a way to calculate speeds and feeds for pocketing in D2 tool steel and also calculate ramping feed rate.

during my meetings with shop programmers i have found out that some people did not really understand the functionality behind Helical Ramping calculator. A more detailed video on Circular Compensation and Ramping to follow.

This video is already on my YouTybe channel:

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Resources and Software For High-Performance CNC Machinists

Hi-Feed Milling at 600 ipm!

Machinists Spoke and We Listened

So the New features are:

Let's go over the most important ones here:

Lesson 4: Essential Stuff about Work Offsets, Tool Length Offsets, G54-G59, Part Zero, G43 H

Machine Home and Machine Coordinates: G53

Key factors Determining Success of High Speed Machining (HSM)

HSMAdvisor v1.181

Major Machine Profiles Updates in This release:

The. First. Ever. HSMAdvisor hook for MasterCAM X9

HSMAdvisor v1.150 released

New and updated features

FSWizard 1.40 Released

I have just finished uploading the latest update for FSWizard apps to both iOS and Android stores.

Here are just some of the changes in the latest version v1.40

First FSWizard video!

HSMAdvisor v1.120