I. What is High-Feed Milling?
High-Feed Milling (abbreviated as HFM) is an advanced milling strategy in modern CNC machining. Its core feature is "small cutting depth and high feed rate". Compared with traditional milling methods, this technology employs extremely small axial cutting depth (usually ranging from 0.1 to 2.0 mm) and extremely high per-tooth feed rate (up to 5-10 times that of traditional milling), combined with a high spindle speed, to achieve an astonishing feed rate.
The revolutionary nature of this processing concept lies in its complete transformation of the direction of cutting force, converting the harmful radial force generated in traditional milling into beneficial axial force, thereby making high-speed and efficient processing possible. The fast feed milling head is precisely a specialized tool designed to implement this strategy and has become an indispensable processing tool in modern mold manufacturing, aerospace, and automotive industries, among others.
II. The Working Principle of the High-Feed Milling Cutter
The secret behind the high-feed milling cutter lies in its unique small main angle design. Unlike traditional milling cutters with a 45° or 90° main angle, the fast feed milling cutter head typically adopts a small main angle of 10° to 30°. This change in geometry fundamentally alters the direction of the cutting force.
Mechanical transformation process: When the blade comes into contact with the workpiece, the small main rake angle design causes the cutting force to mainly point in the axial direction (along the axis of the tool body) rather than the radial direction (perpendicular to the axis) as in traditional milling. This transformation results in three key effects:
1. Vibration suppression effect: The huge axial force pulls the cutter disc "towards" the main shaft, causing the cutter tool - main shaft system to be in a tense state. This effectively suppresses vibration and flutter, enabling smooth cutting even under large overhang conditions.
2. Machine protection effect: The axial force is borne by the thrust bearing of the machine's main shaft. Its bearing capacity is much higher than that of the radial bearings, thereby reducing damage to the main shaft and extending the equipment's lifespan.
3. Feed enhancement effect: Eliminates vibration limitations, enabling the tool to handle extremely high feed rates per tooth. The feed speed can reach 3 to 5 times that of conventional milling, with the maximum speed reaching over 20,000 mm/min.
This ingenious mechanical design enables the rapid feed milling head to maintain a high metal removal rate while significantly reducing cutting vibration, laying the foundation for high-quality surface processing.
III. The Main Advantages and Characteristics of the High-Feed Milling Cutter
1. High-efficiency processing: The most notable advantage of the high feed milling cutter is its outstanding metal removal rate (MRR). Although the axial cutting depth is relatively shallow, the extremely high feed speed completely compensates for this deficiency. For example, when a common gantry milling machine uses a fast feed milling head to process tool steel, the feed speed can reach 4,500 - 6,000 mm/min, and the metal removal rate is 2 - 3 times higher than that of traditional milling cutters.
2. Excellent surface quality: Due to the extremely smooth cutting process, rapid feed milling can achieve excellent surface finish, typically reaching Ra0.8μm or even higher. In many cases, the surfaces processed by using rapid feed milling heads can be directly used, eliminating the semi-finishing process and significantly shortening the production process.
3. Remarkable energy-saving effect: Research shows that the energy consumption of rapid feed milling is 30% to 40% lower than that of traditional milling. The cutting force is efficiently utilized for material removal rather than being consumed in the vibration of the tool and machine, achieving true green processing.
4. It can significantly extend the service life of the tool system: The smooth cutting process reduces the impact and wear on the tool, and the tool life can be increased by more than 50%. The low radial force characteristic also reduces the burden on the machine tool spindle, making it particularly suitable for old machines with insufficient rigidity or for large-span processing scenarios.
5. Advantages of processing thin-walled parts: The extremely small radial force enables the high feed milling cutter to be an ideal choice for processing thin-walled and easily deformed parts (such as aerospace structural components, automotive body mold parts). The deformation of the workpiece is reduced by 60%-70% compared to traditional milling.
Reference for typical processing parameters of the high feed milling cutter:
When using a high feed milling cutter with a diameter of 50mm and equipped with 5 blades to machine P20 tool steel (HRC30):
Spindle speed: 1,200 rpm
Feed rate: 4,200 mm/min
Axial cutting depth: 1.2mm
Radial cutting depth: 25mm (side feed)
Metal removal rate: Up to 126 cm³/min
IV. Summary
The high feed milling cutter is not merely a tool; it represents an advanced processing concept. Through ingenious mechanical design, it transforms the disadvantages of cutting force into advantages, achieving a perfect combination of high speed, high efficiency, and high precision processing. For mechanical processing enterprises facing pressure to increase efficiency and meet high-quality processing requirements, the rational application of the fast feed milling head technology is undoubtedly a strategic choice to enhance competitiveness.
With the continuous development of CNC technology, tool materials and CAM software, the rapid feed milling technology will continue to evolve, providing strong technical support for the intelligent transformation and upgrading of the manufacturing industry. Immediately incorporate the rapid feed milling cutter head into your production process and experience the transformative effect of efficient processing!
Post time: Sep-03-2025
