Feedrate optimization for 2.5D milling operations

Abstract

Presented research is focused on CNC milling operations of planar contours with flat end mills. Paper presents a set of functions requred for processing the workpiece model and NC part program in order to reconstruction the instantneous area of workpiece engaged by the tool. A Z-map interpretation of workpiece was chosen. Reconstructed engagement map, with previously obtained specific cutting forces, is enough for prediction of instantaneous and representative milling forces in points of programmed toolpath. Further, in order to maintain a specified level of milling force, the correction of the feedrate in toolpath points and then rediscretization of the path is enabled. Paper presents an example of experimental identification of speciffic cutting forces and the results of applications of the procedures, developed in Matlab, for optimization of feedrates. Results obtained through experiments are used for discussion of advantages and limitations of applied models.