Robust feedrate selection for 3-axis NC machining using discrete models

This research effort is focused on improving the efficiency of CNC machining by automatic computer selection of feedrate for 3-axis sculptured surface machining. A feedrate process planner for complex sculptured end milling cuts is developed from mechanistic and geometric end milling models. The selection program uses tool deflection, surface finish, tool failure and machine power to set constraints on the cutting force and the feed-per-tooth for rough, semi-finish passes. A NC part program is processed one tool move at a time by the planner. For each tool move a geometric model calculates the cut geometry, and an inverse mechanistic model uses this information along with the constraint force to calculate a desired feedrate. The feedrate is written into the part program resulting in a file that contains a feedrate for each tool move. Experimental results for a sculptured surface show the accuracy of the algorithms in maintaining a desired force.