I've 3 questions...
a) What are the variation of the cutting forces for up and down miling?
b) What's the significance of uncut chip thickness?
c) Any ways to reduce power consumption for a given set of cutting conditions?
Climb milling should result in about 1/3 the horsepower requirement for metal cutting, if you have ball screws on your machine. It will also usually improve surface finish on final cuts.
Use of coolant with solid end mills will also reduce tool wear and conduct heat and chip away from the cutting area. This will result in the cutters staying sharp for a longer time period. Sharp unobstructed cutters take less horsepower than dull ones.
Fred Smith - IMService