29TH DAAAM INTERNATIONAL SYMPOSIUM ON INTELLIGENT MANUFACTURING AND AUTOMATION DOI: 10.2507/29th.daaam.proceedings.063 COMPARISON OF HIGH FEED MACHINING WITH CONVENTIONAL MILLING IN TERMS OF DIMENSION ACCURACY AND PRODUCTIVITY Marcel Kuruc*, Marek Vozár, Vladimír Šimna, Tomáš Vopát, Róbert Hrušecký, Ján Milde, Ivan Buranský, Martin Necpal & Jozef Peterka This Publication has to be referred as: Kuruc, M[arcel]; Vozar, M[arek]; Simna, V[ladimir]; Vopat, T[omas]; Hrusecky, R[obert]; Milde, J[an]; Buransky, I[van]; Necpal, M[artin] & Peterka, J[ozef] (2018). Comparison of High Feed Machining with Conventional Milling in Terms of Dimension Accuracy and Productivity, Proceedings of the 29th DAAAM International Symposium, pp.0426-0434, B. Katalinic (Ed.), Published by DAAAM International, ISBN 978- 3-902734-20-4, ISSN 1726-9679, Vienna, Austria DOI: 10.2507/29th.daaam.proceedings.063 Abstract Numerous industrial enterprises are forced to increase productivity if they want to stay competitive in the market. Therefore, there were performed many researches focused on possibilities of cost effective increasing the productivity. There were created advanced processes and new machining strategies, which could be improved by new cutting materials, advanced coatings and modified geometry. One of the cost effective methods to increase productivity is High Feed Machining (HFM). This method does not require high speed spindle (in contrast with High Speed Cutting – HSC). Moreover, it does not require any special devices or conditions. HFM can be performed on the modern machine tools. This article compares conventional milling and high feed machining of the reference steel materials – C45 by creating some basic shapes and features, such as horizontal and vertical surfaces, cylinders, grooves, etc. Results of the experiment could be applied to determine when HFM is advantageous and what advantages it brings about. Keywords: high feed machining; dimension accuracy; productivity; reference steel; advanced machining 1. Introduction High feed machining (HFM) is known as an effective roughing strategy with substantially higher material removal rate than conventional milling. With higher feed, the surface roughness is increasing as well [1]. This disadvantage is partially reduced by advanced tool geometry (Fig. 1). HFM in contrast with conventional milling is using much higher feeds (approx. 10 times higher). However, it can cause a significant increase in cutting force [2]. Therefore, in HFM, decreased depth of cut (DOC) is used along with the decreased lead angle of the milling cutter. This influences the section of the cut layer resulting in a change of direction of cutting force in a positive way, so that the cutting force is directed towards the spindle, decreasing machine load and reducing vibrations during the machining process. It also changes how the chip is formed during the milling process, causing a lower chip width than the feed per tooth. - 0426 -