Although the machine tool itself must be robust and well equipped enough for high speed machining, the real magic lies in the toolpath generated by today’s advanced CAM software packages. The ability to produce a cutter path with a consistent chip load and tool engagement - especially in the corners - is really the secret sauce to the whole process. The finite control of the toolpath, and the ability to consistently control the amount of material engagement the tool will encounter, allows for dramatic increases in the cutting parameters. Even small diameter tooling can be pushed far beyond traditional limits.
The traditional toolpath cuts in a “racetrack” pattern, simply following the overall shape of the feature being machined, and the process itself lacks the control parameters necessary for increased performance. Traditional ToolpathThis lack of control means that the tool can encounter a varying amount of material – especially in the corners – that will negatively impact the cutter’s ability for going faster. Due to the increased linear forces and stress on the cutter, the depth of cut, rpm, and feedrate must be reduced…and due to the presence of added friction, coolant is most often necessary for a successful outcome. In addition to the heat buildup caused by this friction, the intermittent over-engagement of the process will also cause extreme tool wear, and overall tool life will be much less than could be achieved with high speed machining practices.