After being away from this thread for some time I've come to a conclusion. One of our original topics was "what is the single most important factor in HSM". I realize everything we've talked about is a factor. High Pressure coolant, tool dynamic's, fixturing, control, etc... but, I feel Scott_Bob is right. The single most contributing factor in HSM is the control. Without it, the rest can never acheive their optimal performance levels regardless of all the other things we've talked about. The other things discussed can help a bad machine / cutter work better but, you can only optimize the cutting condition based on the capabilities of the existing control. If your control can't handle HSM machining, nothing else you do will make it work.
Gunner