Research on cutting force revealed that the cutting force decreases as cutting speed increases, which is in line with Salomon’s Theory. However, the fundamental behaviour was never clearly explained because most studies had focused on increasing the cutting speed by increasing spindle speed without retaining the rate of chip load. On that note, the effect of increasing spindle speed while chip load is constant on the cutting force of Hastelloy X is presented in this paper. Third Wave AdvantEdge software was applied and half-immersion up-milling simulations were conducted in dry condition. Result showed that the resultant force was primarily affected by the axial force, followed by normal force and feed force. Trend-lines indicated that the behaviour of cutting force components and resultant force was quadratic. Desirability Function Analysis (DFA) results revealed that the optimum combination of chip load and spindle speed led to lowest cutting force components and resultant force was at 0.013 mm/tooth and 24,100 RPM. Furthermore, the optimum cutting conditions that led to the lowest cutting force components and resultant force at chip loads of 0.016 mm/tooth and 0.019 mm/tooth was 24,100 RPM also. Therefore, increasing Material Removal Rate (MRR) while minimizing cutting force components and resultant force can be achieved by increasing the amount of chip load at spindle speed of 24,100 RPM.

Cutting force is vital in machining nickel-based superalloys due to their excellent mechanical properties, thus creating difficulty in cutting. In the current scenario of metal machining, milling processes require high spindle speed and low chip load, which result in a low cutting force. However, low chip load not only result in low cutting force but also result in a low material removal rate (MRR). It is contrary to the ultimate high-speed machining (HSM) goal, which is to improve productivity and cost-effectiveness. Therefore, the emergence of an approach for achieving simultaneous low cutting force and high MRR is crucial. This paper presents the effect of increasing spindle speed at a constant chip load on the cutting force of Hastelloy X during half-immersion up-milling and half-immersion down-milling. In both half-immersions, the simulation results and experimental results are in good agreement. The percentage contribution of feed force, normal force and axial force to the resultant force can be arranged descendingly from high to low as axial force > normal force > axial force. Moreover, feed force, normal force, axial force and resultant force have a U-shaped behaviour. The spindle speed of 24,100 rpm and a chip load of 0.019 mm/tooth were found to achieve both low cutting force and high MRR.

The impact of COVID-19 pandemic to manufacturing companies has been horrendous that panic attack has occurred among the companies, as well as semiconductor companies. Many companies have been declared bankrupt due to this pandemic and a new normal have been born such as remote working, following by certain Standard Operating Procedures (SOPs) implemented by the government to avoid infection of this COVID-19 virus and practice social distancing at the workplace. Apart from the new normal, there are some effects to the semiconductor companies in a way that could present a negative impact to the future of the companies. There are some drastic measures being implemented to adapt with the new normal as well as keeping the production running as usual. The main motive of analyzing the current situation is to avoid complete down fall of production of semiconductor companies which may affect the global economy.

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