Estimation of Machining Time in High Speed Milling of Prismatic Parts

A methodology was developed to estimate the machining time in high speed milling operations of prismatic parts. The machine tool acceleration rate and the tool path geometry are the main factors that determine the machining time at high feed rates. Machined test parts were used to measure the machine tool acceleration rate and the influence of changes in tool path direction on the actual feed rate. A simple mathematical model to estimate machining time was developed and calibrated. Experimental verification showed that machining time could be estimated within 3% of the actual time, for milling operations at feed rates up to 16 m/min.