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High-speed cutting is one of the key issues in mould manufacturing. But to apply high-speed milling to mould manufacturing, unlike conventional milling, it is necessary to define specific cutting parameters. This article aims to define the influence of milling strategies and cutting parameters, such as cutting speed, feeding speed, cutting tool tilting angle, on the process stability.Long tool life and cutting strategy have a major influence on the results of machining hardened steel. Machining with drawing cut and down-cutting in copper and with drawing cut and up-cutting in hardened steel gave the best results with respect to tool wear and surface quality. Tool approach across the feeding direction results in heavy impact loads on the tool which lead to heavy tool wear and substantial dimensional deviations.Good surface quality is achieved in machining of a work piece of 2 363 steel (X100CrMoV51) hardened to 60 HRC, using the strategy of up-cutting with drawing cut and a tool approach with a tilting angle of 15 degrees. While up-cutting allows for achieving better surface quality, down-cutting provides longer tool life than up-cutting for all angles of approach.

Computational modeling of distortion can minimize costly distortion corrections, and improve quality.  The accuracy of this approach is highly dependent on the modeling of the heat source.  The angular distortion found to be affected by welding speed, current, material thickness, penetration depth and pre-welding gap between plates. However, although it is said that there is a relationship between all inputs, there is no method to formulate how much they cause distortion.  Quantifying the weld distortion is a challenging procedure. An adequate way to validate this type of study is to use precision measurement tools such as optical 3D scanner and coordinate measuring machine (CMM).