Fundamentals of precision in high speed milling

The development of new carbide and ceramic cutting tools offers great potential for increased cutting speeds. Higher speed spindles, improved bearings and bearing lubrication systems, advances in spindle cooling equipment and more rigid machine tool structure are a response to this promise. Higher productivity, the elimination of chatter and longer tool life have been the primary objectives of these developments. As a result, in 'state-of-the-art' machines, contouring speed is often limited by the requirement for profile accuracy or CNC (computer numerical control) processing speed, not by physical metal removal rates. The principle factors affecting accuracy in high speed milling are generally considered to be: machine rigidity and accuracy; cutter design and stiffness; servo lag; and control processing speed.