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Variable Feed Optimization Based on Outside/Inside Arc Velocity

Variable Feed Optimization Based on Outside/Inside Arc Velocity

We currently have the "Feed Optimization" setting which lowers the feed when a certain threshold in directional change is met. This is suitable for sharp angle changes perhaps, but rather clunky compared to the grace inherent to adaptive clearing.

 

A more mathematically sound model would instead calculate the cut's true feed rate based on which side of the cutter is engaging the material. When making any arcing cut, using the center of the tool to determine feed is an inaccurate approximation. The outside of the cutter will make a significantly larger arc (depending on the arc angle), thus is cutting at a significantly higher feed rate. Likewise, the inside edge is cutting far slower. An ideal feature would decrease (and increase, as a separate option) feed proportional to these differences in velocity, thus ensuring similar IPT regardless of whether it is an inside corner or a straight edge.

 

The phenomenon of central vs edge feedrate is well-documented for thread milling, (See: http://www.mmsonline.com/articles/get-the-feed-rate-right-when-thread-milling ), yet it seems to mostly go unmentioned for standard operations. As adaptive and trochoidal pathing becomes more common and the tools spend more time cutting in arcs, its importance only increases. The article linked mentions that some machines may already have mechanisms to compensate for this but there simply is no way your machine can tell for certain which side of your tool is engaging material - thus it remains a problem that only CAM can solve properly.

1 Comment
davidGLA8P
Enthusiast

I encountered this problem today.  I couldn't understand why a pair of 2d profile ops - one on the outside, the other on the inside of the same cylinder - had radically different estimated execution times - think 3s vs 9s.  Of course the path of the centre of the tool on the inside cut is much shorter than on the outside.  So the ipt and material removal rate on the inside pass is much larger than programmed.

 

Not unreasonable on a 2d profile, but I was very surprised to find that 2d and 3d adaptives gave the same result.  Since I frequently drill a hole not much bigger than an end mill and use that as a pre-drilled entry position for adaptive pocket clearing, the initial ipt must be enormous.  I suspect the only reason I don't break tools because of this is that my mill's limited x and y accelerations mean it doesn't get close to the programmed feed when the diameter of the tool path is still small.

 

Not very clever.

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