No worries, no offence taken. You're right, making a milling machine, especially a higher speed one, is a daunting task. But isn't that what drives us? I'm only really happy when I'm solving an almost impossible problem. |
I certainly agree with you, and I also take great satisfaction in solving difficult problems. However, you said this was company related project, which means money and time is involved. I fear the time and money you may spend to achieve an acceptably performing machine may outweigh personal satisfaction and experience you will gain. I highly suggest throwing money at this problem!
I wouldn't bother with the strain gage...like I said earlier, your cutting forces are the LEAST of your concerns. F=ma should be your primary concern.
For instance, even on my machines, cutting feed at over 12,000 mm/min, the servo loads are low...around 15-20%, but when accelerating/decelerating the axis, spindle loads often exceed 100% load. (often, the axis perpendicular to the feed axis will show the higher load)