The Hierarchy of Optimization
Not all optimizations are equal. Saving 2 seconds on a tool change doesn't matter if your roughing pass takes 30 minutes. Focus on the big wins first.
1Kill the "Air Cuts"
Impact: High
"Air cutting" is when the tool is feeding but not touching material. Check your CAM rapid height settings. Are you retracting to Z5.0" between every hole? Optimize traverse moves to stay closer to the part (e.g., Z0.1" or using "Dog Leg" rapids if safe).
2Use HSM (High Efficiency Milling)
Impact: Very High
Stop taking shallow, wide cuts. Switch to High Efficiency Milling (HEM): deep axial depth (2-3x Dia) with small radial stepover (10-20%). This allows you to double or triple your feed rate due to Chip Thinning and better heat dissipation.
3Optimize Tool Changes
Impact: Medium
A tool change takes 3-10 seconds. If you swap tools 20 times, that's 2+ minutes. Combine operations. Can you use the same 1/2" End Mill for both roughing and finishing flat surfaces? Can you spot drill with the chamfer tool?
4Use High-Feed Mills
Impact: High (Roughing)
For removing bulk material, nothing beats a High-Feed Mill. The low lead angle (10-15°) directs forces axially into the spindle, allowing extreme feed rates (100-300+ IPM) even on lighter machines.
The "10 Percent" Rule
Once your program is running well, try increasing the Feed Rate Override to 110%. Listen to the tool. If it sounds happy, verify the part dimensions. If good, update the CAM program. A 10% reduction across a year of production is basically a "free month" of machine capacity.