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<p>This paper introduces an innovative modular CNC toolpath strategy for the milling of circular and regular polygonal pockets. The method integrates two adjustable motion components, a three-dimensional helical descent and a two-dimensional spiral path, based on parametric interpolation algorithms with variable radius, pitch, and step-over. Cutting conditions, including spindle speed and feed rate, are independently configurable for each stage. In the case of circular pockets, these motions are combined into a continuous sequence that achieves both roughing and finishing. Although circular pocket machining has long been supported by conventional canned cycles and extensively studied in the literature, opportunities remain for alternative strategies that expand user choice, improve adaptability, and provide controller-level flexibility. For polygonal pockets, the helical–spiral motions are used to clear the interior volume up to a safe boundary, followed by a separate contouring phase to accurately define the final geometry. The complete strategy is implemented as a custom G-code routine suitable for integration into CNC controllers as a dedicated canned cycle, reducing dependence on external CAM software. The method is exportable as a G01-only program, enabling execution on CNC systems without canned cycle or macro capabilities. MATLAB simulations and CNC-based tests demonstrate the geometric consistency and adaptability of the toolpath generation process across different pocket configurations. A comparative cycle time analysis against conventional canned cycles and CAM-generated toolpaths highlighted the strategy’s efficiency, showing that it can stand as a competitive alternative. Additionally, a physical machining test on a CNC milling machine confirmed the method’s practical feasibility.</p>

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An integrated helical–spiral motion strategy for CNC machining of circular and polygonal pockets

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月4日

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  • Sotiris Omirou,
  • Marios Charalambides,
  • George Demosthenous

摘要

This paper introduces an innovative modular CNC toolpath strategy for the milling of circular and regular polygonal pockets. The method integrates two adjustable motion components, a three-dimensional helical descent and a two-dimensional spiral path, based on parametric interpolation algorithms with variable radius, pitch, and step-over. Cutting conditions, including spindle speed and feed rate, are independently configurable for each stage. In the case of circular pockets, these motions are combined into a continuous sequence that achieves both roughing and finishing. Although circular pocket machining has long been supported by conventional canned cycles and extensively studied in the literature, opportunities remain for alternative strategies that expand user choice, improve adaptability, and provide controller-level flexibility. For polygonal pockets, the helical–spiral motions are used to clear the interior volume up to a safe boundary, followed by a separate contouring phase to accurately define the final geometry. The complete strategy is implemented as a custom G-code routine suitable for integration into CNC controllers as a dedicated canned cycle, reducing dependence on external CAM software. The method is exportable as a G01-only program, enabling execution on CNC systems without canned cycle or macro capabilities. MATLAB simulations and CNC-based tests demonstrate the geometric consistency and adaptability of the toolpath generation process across different pocket configurations. A comparative cycle time analysis against conventional canned cycles and CAM-generated toolpaths highlighted the strategy’s efficiency, showing that it can stand as a competitive alternative. Additionally, a physical machining test on a CNC milling machine confirmed the method’s practical feasibility.