What is a common result of using a dull tool in milling operations?

Using a dull tool in milling operations typically results in increased cutting forces. This occurs because a dull cutting edge cannot efficiently slice through the material, causing it to exert more force against the workpiece to achieve the desired cut. As a result, operators may need to apply greater pressure to maintain feed rates, which can lead to adverse effects such as excessive tool wear and potential machine strain.

In contrast, enhanced surface finish, lower energy consumption, and faster operational speed are generally associated with sharp, well-maintained tools. A dull tool compromises the quality of the cut and the overall efficiency of the milling process, underscoring the importance of tool maintenance and replacement in manufacturing operations.