The Test Lab helps you dial in optimal cutting parameters for your specific machine, tool, and material combination. Instead of guessing or using generic settings, you'll run a few test cuts and let the system guide you to your machine's sweet spot.
The Core Concept: Chipload
Chipload is the thickness of material each flute removes per revolution. It's the single most important factor in cut quality.
For example: 100 ipm ÷ (14,000 RPM × 2 flutes) = 0.00357" = 3.57 thousandths
Why Chipload Matters
| Chipload | Result |
|---|---|
| Too Low (<2.5 thou) | Rubbing instead of cutting. Creates dust, heat, and friction. Burns wood, melts plastic, wears tools fast. |
| Optimal (3-5 thou) | Clean cutting action. Nice chip curls, cool tool, smooth sound, clean edges. |
| Too High (>6 thou) | Overloading the tool. Causes chatter, deflection, torn edges, potential breakage. |
Key Insight: The same chipload can be achieved many ways. Your machine determines which combination works best. Lighter machines often perform better at lower RPM with moderate feed.
The Two-Phase Process
Phase 1: Dial-In
Goal: Find the feed/RPM combination that produces optimal cut quality on YOUR machine.
- Run a test cut with starting parameters
- Score the cut quality (4 metrics)
- System adjusts both feed AND RPM
- Repeat until optimal
Typical: 2-3 tests to reach optimal
Phase 2: Scale
Goal: Increase cutting speed while maintaining optimal chipload.
- Increase both feed and RPM by 15%
- Run a test cut
- If quality stays optimal, repeat
- When quality drops, back off one step
Result: Maximum throughput for your machine!
The Four Quality Metrics
| Metric | Good (3) | OK (2) | Poor (1) |
|---|---|---|---|
| Edges | Clean and crisp | Fuzzy/tearout | Torn/ragged |
| Chips | Curly chips | Small flakes | Fine dust |
| Sound | Smooth hum | Slightly rough | Screaming/chatter |
| Heat | Cool to touch | Warm | Hot/smoking |
How Adjustments Work
| Score | Severity | Feed Δ | RPM Δ |
|---|---|---|---|
| 4-5 | Terrible | ±20% | ±25% |
| 6-7 | Poor | ±10% | ±20% |
| 8-9 | Mediocre | ±5% | ±15% |
| 10-11 | Close | ±5% | ±12% |
| 12 | Optimal! | → Offer Scaling | |
Common Patterns & Solutions
Dust + Heat + Screech
Diagnosis: Severe rubbing → Solution: Drop RPM 25%, raise feed slightly
Chatter + Torn Edges
Diagnosis: Overload → Solution: Drop feed, possibly raise RPM
Good Chips but Hot Tool
Diagnosis: RPM too high → Solution: Drop RPM, keep feed steady
Tips for Best Results
Before Testing
- Use fresh/sharp tooling
- Secure workpiece firmly
- Use consistent material
- Let spindle warm up
During Testing
- Listen to the cut
- Watch chip formation
- Feel tool after cut
- Check edges under light
Understanding Your Machine's Limits
| Constraint | Symptom | Solution |
|---|---|---|
| Spindle power | Bogs down | Reduce DOC or feed |
| Frame rigidity | Chatter at good chipload | Lower feed, shallower cuts |
| Motor torque | Lost steps | Slower rapids |
Frequently Asked Questions
How many test cuts should it take?
Typically 2-3 tests to dial in, then 3-5 scaling tests for max throughput.
What if I can't get a good cut?
Check fundamentals: tool sharpness, workholding, machine maintenance.
Do I need to redo this for every project?
No. Once dialed in, settings work consistently. Retest only if tools/materials change.