Enhanced Computer Numeric Controller Milling Efficiency via Air-Cutting Minimization Using Logic-Based Benders Decomposition Method

In computer numeric controller (CNC) milling machining, air-cutting, where the tool moves without engaging the material, will reduce the machining efficiency. This study proposes a novel methodology to detect and minimize non-productive (air-cutting) time in real-time using spindle load monitoring, vibration signal analysis, and NC code tracking. A logic-based benders decomposition (LBBD) approach was used to optimize toolpath segments by analyzing air-cutting occurrences and dynamically modifying the NC code. Two optimization strategies were proposed: increasing the feedrate during short air-cutting segments and decomposing longer segments using G00 and G01 codes with positioning error compensation. A human–machine interface (HMI) developed in C# enables real-time monitoring, detection, and minimization of air-cutting. Experimental results demonstrate up to 73% reduction of air-cutting time and up to 42% savings in total machining time, validated across multiple scenarios with varying cutting parameters. The proposed methodology offers a practical and effective solution to enhance CNC milling productivity.