What is the potential impact of high vibration levels during milling?

High vibration levels during milling can significantly contribute to increased tool wear. When vibrations occur, they can lead to unpredictable and excessive forces on the cutting tool and workpiece. These forces can cause the cutting edges of the tool to degrade more quickly than they would under stable operating conditions. As a result, the tool may become dull or damaged sooner, necessitating more frequent replacements and potentially leading to additional costs.

Moreover, increased vibrations can directly affect the quality of the machined surface. The erratic behavior of the tool, influenced by vibrations, may result in poor surface finish and reduced accuracy in dimensions. Additionally, high vibration levels can also compromise the stability of the milling process, leading to further complications such as chatter, which can severely damage both the workpiece and the tooling.

In contrast, factors like greater tool lifespan, improved surface quality, and improved cutting efficiency are not typically associated with high levels of vibration. Instead, these favorable outcomes usually occur in stable, well-controlled milling conditions where vibration is minimized.