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<title>Optimization Results | HiAPI-C# 2025 </title>
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<article data-uid="Technique-OptimizationResults">
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<h1 id="optimization-results">Optimization Results</h1>
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<p>Two measured before-and-after comparisons. Both were run on real machines with the same cutter
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and the same geometry, changing only the feed rates in the NC program.</p>
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<h2 id="hardened-mould-3-axis--fdac">Hardened Mould, 3-Axis — FDAC</h2>
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<p><img src="optimization-results-img/fdac-mold-sim.jpg" alt="FDAC mould simulation"></p>
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<p><strong>Bull nose cutter</strong></p>
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<table>
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<thead>
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<tr>
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<th></th>
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<th>Fixed feed</th>
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<th>Optimized feed</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td>Feed rate</td>
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<td>120 mm/min</td>
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<td>variable</td>
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</tr>
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<tr>
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<td>Expected machining time</td>
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<td>303 min</td>
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<td>95 min (31%)</td>
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</tr>
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<tr>
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<td>Tool breakage</td>
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<td>at 217 min</td>
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<td>none</td>
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</tr>
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</tbody>
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</table>
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<p>The time figure is the headline, but the breakage row is the result worth having: the fixed-feed
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run did not complete. An optimized program that finishes is not comparable to an unoptimized one
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that does not.</p>
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<p><strong>Ball cutter</strong></p>
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<table>
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<thead>
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<tr>
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<th></th>
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<th>Fixed feed</th>
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<th>Optimized feed</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td>Feed rate</td>
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<td>220 mm/min</td>
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<td>variable</td>
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</tr>
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<tr>
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<td>Machining time</td>
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<td>125 min</td>
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<td>74 min (59%)</td>
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</tr>
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<tr>
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<td>Measured wear depth</td>
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<td>50 µm</td>
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<td>20 µm (40%)</td>
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</tr>
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</tbody>
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</table>
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<p>The wear depth here is <strong>measured on the cutter</strong>, not simulated:</p>
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<p><img src="optimization-results-img/fixed-feed-cutter-wear.png" alt="Wear after the fixed-feed run">
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Fixed feed</p>
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<p><img src="optimization-results-img/opt-feed-cutter-wear.png" alt="Wear after the optimized run">
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Optimized feed</p>
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<h2 id="free-form-roughing-5-axis--ti6al4v">Free-Form Roughing, 5-Axis — Ti6Al4V</h2>
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<p>Simulated comparison on a five-axis free-form roughing program in titanium:</p>
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<table>
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<thead>
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<tr>
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<th></th>
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<th>Original NC</th>
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<th>Optimized NC</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td>Machining time</td>
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<td>181 s</td>
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<td>79 s (56% reduction)</td>
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</tr>
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<tr>
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<td>Tool wear</td>
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<td>13.1 µm</td>
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<td>8.9 µm (32% reduction)</td>
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</tr>
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<tr>
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<td>Breakage risk</td>
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<td>high, from overcut; low yield</td>
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<td>overcut breakage eliminated</td>
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</tr>
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</tbody>
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</table>
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<p>Both figures here are simulated rather than measured, and should be read as such — the
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comparison is sound because both sides come from the same model, which is the same argument that
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applies to the quoted times.</p>
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<h2 id="reading-these-numbers">Reading These Numbers</h2>
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<p>The times are ideal-feed estimates and omit controller dynamics on both sides of every
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comparison, so the <strong>ratio</strong> is the trustworthy part and the absolute is not — see
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<a href="../nc-optimization/machining-time-estimation.html">Machining Time Estimation</a>.</p>
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<h2 id="see-also">See Also</h2>
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<ul>
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<li><a href="../nc-optimization/nc-optimization-principles.html">NC Optimization Principles</a> — what the optimizer changed to produce these reductions</li>
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<li><a href="../nc-optimization/machining-time-estimation.html">Machining Time Estimation</a> — why the ratio in these tables is sounder than the absolute</li>
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</ul>
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</article>
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