I don't know if anyone would consider this HSM, but it seems to be a problem that is related. I'm trying to machine some 35 2 inch cubes of aluminum and needing to remove quite a lot of material from them, I went out and found a 1/2 SC Zirconium coated end mill and was set to more or less max out my TOYODA 45V at 9000rpm and around 140 ipm. However, when I try to run a cut that fast, the cutter seems to undercut, as in cut a sharper concave curve than it is programmed for, this is very obvious on the piece because the EM is followed by a roundover on the same cutpath. My first thought was deflection or backlash, however running the path twice in a row dosen't fix it so it is not an issue of cutting forces, its almost like the control is overcompensating for the acceleration it needs to do around that U shaped contour, the problem goes away only when I lower the feedrate. I apologize if this is a no-brainer, we are not a machine shop and I am not a machinist, just the guy who runs the machines
Any thoughts would be very appreciated