Optimization of CNC Machining Feed Rate Using S-Curve Algorithm-Enhanced G-Code

This study presents a novel method for optimizing feed rate in CNC machining by integrating the S-curve algorithm into G-code programming. The objective is to enhance machining performance by reducing vibration and improving surface quality. A middleware tool was developed to automatically transform conventional G-code into S-curve-optimized G-code. Experimental validation was performed on a four-axis CNC machining center, using a 40 mm diameter milling cutter with standard indexable inserts to machine medium-carbon steel workpieces. The S-curve-optimized G-code dynamically adjusted feed rates during critical phases, including tool entry, exit, and steady-state cutting. Vibration data were collected using an industrial-grade vibration analyzer, and surface roughness was measured with a precision surface profilometer. Results show that the S-curve-enhanced G-code significantly reduces vibration amplitudes and yields improved surface finishes compared to conventional G-code. These findings highlight the potential of the proposed method to increase machining efficiency, improve product quality, and extend tool life in CNC milling operations.