Conventional tool-path generation strategies are readily available to generate geometrically feasible trajectories. Such
approaches seldom take into consideration physical process concerns or dynamic system limitations. In the present
work, an approach for improving a geometrically feasible tool-path trajectory based on quantifiable process metrics is
developed. Two specific measures of toolpath quality are incorporated into the iterative improvement algorithm:
instantaneous path curvature and instantaneous cutter engagement. These metrics are motivated by a desire to
minimize acceleration requirements and maintain a stable steady-state cutting process during high-speed machining.
The algorithm has been implemented for two-dimensional contiguous end-milling operations with flat end-mills, and
case studies are presented to illustrate the approach.
Keywords: high-speed machining, tool-path, engagement, curvature
High speed machining (HSM) is a key enabling technology in an increasing number of industries. In the aerospace
industry, structural components are increasingly being machined as monolithic structures from a single billet. The
result is drastically reduced part counts, assembly costs, and even maintenance costs. The Boeing F/A 18 E/F tactical
aircraft realized a 42% reduction in parts and a 25% weight savings over previous models, attributed not in small part
to the design changes made practical by the application of high speed machining technology . In the tooling
industry, high speed machining technology continues to grow increasingly important for maintaining economic
competitiveness. Successful applications of HSM to the production of tooling for forging, extrusion, sheet forming,
die casting, and injection molding have been reported [2-4].