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<article data-uid="Technique-MachineCondition">
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<h1 id="machine-condition-and-safety-factors">Machine Condition and Safety Factors</h1>
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<p>Two machines of the same model, one maintained and one not, do not accept the same NC program.
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The simulation models the cut, not the wear state of the machine running it, so the machine's
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condition enters through the safety factors — and setting them honestly is the difference between
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an optimized program that runs and one that only runs in simulation.</p>
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<h2 id="the-simulation-is-valid-only-under-stable-machining">The Simulation Is Valid Only Under Stable Machining</h2>
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<p>Every availability ratio HiNC reports — yield stress, spindle torque, spindle power, thermal
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yield — is a fraction of what the cut is allowed to demand. <strong>The results describe reality only
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while all of them stay under 100%.</strong> Above that the machine is no longer doing what the model
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says it is doing: the spindle droops, the feed per tooth rises, and the divergence grows rather
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than staying proportional.</p>
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<p>Reading those ratios, and what each one means at 100%, is
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<a href="../milling-physics/machinability.html">Evaluating Process Machinability</a>.</p>
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<h2 id="safety-factors-are-where-the-machines-condition-goes">Safety Factors Are Where the Machine's Condition Goes</h2>
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<p>HiNC exposes a safety factor per limiting quantity — spindle power, spindle torque, thermal
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yield — and they feed straight into the optimizer's output. They are not decoration: raising a
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factor lowers the feed the optimizer is willing to assign, across the whole program.</p>
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<p>Use them to describe the machine you actually have. A machine in poor condition should be given
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larger factors, or a lower preferred cutting force, so that the optimized program leaves it more
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headroom. The same program optimized for a well-maintained machine will be faster, and will be
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the wrong program for the worn one.</p>
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<h2 id="see-also">See Also</h2>
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<ul>
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<li><a href="spindle-capability.html">Spindle Capability</a> — the curves the power and torque factors are applied to</li>
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<li><a href="../milling-physics/chatter.html">Chatter, and What the Simulation Does About It</a> — the failure mode the force ceiling exists to avoid, and the two cases it does not cover</li>
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<li><a class="xref" href="../validation/cutting-force.html">Cutting Force and Torque Validation</a> — a worked maximum feed rate, and where the safety factor enters it</li>
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</ul>
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