I honestly ask myself the question:
Are our CNC machines capable of HSM?
What defines High Speed in Steel or harder materials is not High Speed in Aluminum if you're talking about just speeds and feeds.
Camminc, I don't know what data you'd get from your analysis that would discriminate between material that is Rc55, then I suppose you'd have to get a new reading when machining softer material say aluminum right?
The dynamics would not be the same with different material right?
Another thought, If I wait until I get chatter, or audible signs then when finishing with a .062 diameter ball end mill, my experience would suggest that the end mill is no longer any good. Quite often we are finishing with even smaller ball end mills say .032, what then?
Just for clarity, Our data proves that it is the limitation of the CNC control that prevents us from HSM feeds even for steel materials.
Accurate, smooth feeds above F30. inches per minute are not possible. No amount of speed / feed rate compensation can move us to the level of HSM performance. I'm not even talking about aluminum material where feed rates should be above F300. for true HSM.
Sincerely,