Version 8 Feedrate Optimization

Feedrate optimization is a great new feature in version 8.  It is included in FeatureMILL2.5D and FeatureMILL3D.  The concept of feedrate optimization is simple:  use the 3D toolpath simulation to measure the actual load of the tool and then even out the tool load by adjust the feedrates in the program.

Benefits

• Evening out the tool load means less tool wear and less wear on your machine tool.  By creating part programs that cut evenly throughout, your cutting tools will last longer and your machine tool will face less wear and tear.  
• Feedrate optimization can make your programs run faster.   

Sample Part

We'll  use a brake caliper part and study the roughing pass of the top boss.  

Tool Load Graph

After generating toolpaths for the roughing pass, the Op. List indicates a cutting time of 1 minute and 49 seconds and shows an estimated horsepower for the operation to be 1.98.  This is just an estimate.  To get a more accurate picture of the tool load, click the Show Tool Load Button and run a 3D simulation.  

A graph of the load of the tool is displayed.  If you click the Settings button in the graph, it shows that the maximum horsepower of the toolpath is actually 5.9.  

Feed Rate Optimization

Running feedrate optimization is simple.  Just select Feedrate Optimization from the Manufacturing menu.  After it runs, the tool load graph shows a maximum horsepower of 2.3.  The after optimization is run, the graph shows the before and after feedrates for comparison.  The cutting time is still 1 minute and 49 seconds.  This means that the feedrate optimization process reduced the feedrates in corners where the load was high and increased the rates where the loads were low.   

Increasing the Target Horsepower

Now lets assume you have a machine tool that can comfortably cut at a 4 horsepower level.  If the Target Horsepower milling attribute is set 4 and then Feedrate Optimization is rerun, the overall feedrates of the program are raised, while still maintaining a consistent tool load.

The tool load graph now indicates that max horsepower is 4.4.  The Op. List tab indicates that the cutting time is now 1 minute 31 seconds.

Summary

Feedrate optimization is easy to use and in this case it decreased cutting time by nearly 17%.