F2000
Because that's what the tool library said
The feed rate came over from the settings of an older, smaller machine. The new one could run four times faster, but nobody touched it, because nobody knows where the limit is.
Across 61 production files, every cutter at F2000 was running 1.3–4× below its minimum chipload. It rubs instead of cutting, heats up and dulls faster.
X↘ Y↗
The controller brakes, the spindle doesn't
Before a corner, the controller rightly slows down. The spindle speed stays the same, so the chip gets thin and the cutter starts to rub. You see it as burn marks in MDF and shorter tool life.
On a gantry router, a 90° corner costs 0.109 s of braking and accelerating. With thousands of corners in a program, that adds up to minutes with the cutter outside its window.
≈ ?
CAM time estimates ignore braking
CAM divides path length by feed rate. On short segments the machine never gets up to speed, so the real cycle time is longer and the job is quoted too low.
On a 3D decorative panel, a ⌀6 mm ball-nose with an 8,000 mm/min ceiling averaged 1,513 mm/min and took 62% of the cycle time.