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radial depth of cut and a small axial depth of cut, while for thin floor webs (i.e., end cutting), a large axial depth of cut should be combined with a small radial depth of cut. Although the depths of cut are small compared to conventional machining, the feed rates used in high speed machining are so much higher that they allow higher metal removal rates. Another fundamental associated with step cutting is that all cutters have a maximum depth of cut before they chatter; therefore, taking small depths of cut with the step cutting technique helps to prevent chatter, i.e. the cutter remains in the stability zone where chatter does not occur.

The comparison between conventional and high speed machining in Table 2.12 illustrates the small depths of cuts used in high speed machining. Again, since the feed rates are so much higher in high speed machining, the metal removal rate is still much higher.

Attempts to cut extremely thin wall structures using conventional machining are generally unsuccessful. In conventional machining, cutter and part deflection result in cutting through the thin walls as illustrated in Fig. 2.30. As shown,

Table 2.12 Comparison of Conventional and High Speed Machining

Conventional Machining

High Speed Machining

Cutter

Axial Depth of Cut (in.) Radial Depth of Cut (in.) Metal Removal Rate (in.3/min)

1.5 Diameter x 2in. long 3600 40 1 1

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