Feed Rate Optimization Using NC Cutting Load Maps

In CNC (Computer Numerical Control) machining, single-use components including moulds and dies require only a one-time machining process. Therefore, collision checks and optimization of the machining path are carried out through simulation ahead of time. Due to the nature of single-use machining, it is challenging to accurately predict the cutting load for a specific spindle-tool-material combination, as there are many variables involved. The cutting force can be calculated physically based on the tool shape, the material’s specific cutting resistance, and cutting conditions such as cutting width and depth, feed rate, and spindle speed. The predicted cutting force has a similar pattern to the cutting load. However, the cutting load may be different from the cutting force, taking into account factors such as the spindle characteristic curve, temperature, cutting flow, tool wear, etc. Improved product quality, reduced tool wear during machining, and more mindful selection of cutting conditions can be achieved if the predicted cutting force can be acceptably converted into the actual cutting load. This study presents a method for optimizing the feed rate of the tool, which has a direct influence on the cutting load, by converting the cutting force into a cutting load map. The results of the experiment showed that the actual cutting load can be successfully found through the predicted cutting force. These research findings can be applied to single-use machining products through data-based reasoning.