Analysis of the tool path interpolation results on the high feed milling of free form surfaces with sharp edges

Abstract

In this work, the influence of the tool interpolation method on the HSC of free form surfaces with sharp edges is analyzed. The traditional linear interpolation was compared to polynomial interpolation by application of three different values of CAM tolerance. The results were analyzed in terms of machined surface roughness, contour dimensional form error measurements and dynamic behavior of the tool machine, through the real time acquisition of feed rate in x and z axes. It was shown that polynomial interpolation offers accuracy and surface quality gains if compared to linear interpolation, in the same cutting conditions. However the decision for applying both interpolation methods has to consider the CAM tolerance value in terms of lead-time reduction. By using of linear interpolations the programmer has to decide for opener CAM tolerances due to the NC program size and consequently the time to process the program. When the CAM programmer decides for applying polynomial interpolations the CAM tolerance must be closed as soon as possible due to more surface profile adjust to polynomial curve equation.