Analytical and experimental study of feed rate in high-speed milling

In the context of high-speed milling (HSM), during the machining process dynamic machine response has to be identified. To achieve this, we have to calculate the feed rate evolution in linear and circular interpolation according to dynamic performance of machine. In addition to that, actual trajectory for transition passages between two interpolations must be estimated with take into account of specific machining tolerances. This article proposes a model of machine tool behavior for a tool path with linear and circular interpolations and machining cycle time prediction. The method involves subdividing the trajectories into elementary geometries according to the type of interpolation (circular or linear). At points where different trajectories meet, there is often a discontinuity in curvature or in tangency, which decreases the feed rate. At the points of discontinuity in tangency, a fillet radius is inserted. In this article, the influence of the geometry for elementary trajectories was determined. Then, the value of the fillet radius between linear and circular contours in different combinations was modeled. An industrial application was carried out in order to validate models and to determine the influence of feed rate evolution on the machining cycle time