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The calculated coordinates, by definition, are the point's (vector) displacement from the origin. Divide the coordinates by the magnitude of this displacement, $\sqrt{a^2 + b^2}$ (which is some number less than $1$), and you'll arrive at the point midway between the two points, on the unit circle.

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The interpolation you want is a linear interpolation of the angle (which is identical to the arclength for the unit circle): $$ \phi = \phi_a (1-t)+\phi_b t $$ which could involve segments of length more than $\pi$. If the shortest path is wanted, one needs to modify the above.

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Given 2 points on a unit circle, a from position and a to position, how do I interpolate between the two positions given an amount to interpolate by t?

If you have two points, $a=(a_x,a_y)$ and $b=(b_x,b_y)$, then take their sum $c=(a_x+b_x,a_y+b_y)$. Then your point could be $\frac{c}{\|c\|}$ where $\|c\|=\sqrt{c_x^2+c_y^2}$.

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Note: To convert $(x, y)$ to this form, you want $x = 2t/(1+t^2)$ and $y = (1-t^2)/(1+t^2)$. Assuming that $x^2+y^2 = 1$ and the point is in the first quadrant, we get $x(1+t^2)=2t$ or $t^2x-2t+x=0$. Solving $t =\frac{2\pm \sqrt{4-4x^2}}{2x} =\frac{1\pm \sqrt{1-x^2}}{x} $. Since $0 \le x \le 1$, we must choose the negative square root to ensure $0 \le t \le 1$. Since $x^2+y^2 = 1$, $\sqrt{1-x^2} =\sqrt{y^2} = y $. Therefore, $t = \frac{1-y}{x} $. If $x=0$, set $t = 0$.

If you have restrictions on using trigonometric functions and their inverses, then you probably have more restrictions (maybe even no floating point arithmethic). We would need more information on them, to give useful advice. E.g. using symmetry and a lookup table for $\cos$ for the first $1/8$th of the circle might fail due to having not much memory etc.

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20141221 — I'm looking for recommendations on calculating best feed speed when cutting aluminium. My spindle speed on the RF25 ranges from 100rpm up to a max 2150 rpm.

I'm trying to produce movement on a unit circle from one point to another in equal increments, but I'm having trouble doing this without the use of angles (which isn't an option).

If you are willing to use nonlinear interpolation, you can use the old standby of $\left(\frac{2t}{1+t^2}, \frac{1-t^2}{1+t^2}\right) $ for $0 \le t \le 1$. Since $(2t)^2+(1-t)^2 =(1+t)^2 $, this goes on the circle from $(0, 1)$ to $(1, 0)$ as $t$ goes from $0$ to $1$.

The first is calculated via $\arctan(x)$ the second via $\cos(x)$ and $\sin(x)$ or one of them replaced by the square root function.

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This would only need in advance calculation and storage of the segement end points, e.g. $5$ points for the image above with $4$ segments. If you use symmetry only about half of the points are needed.

If you know the coordinates of the two points in Cartesian coordinates $(x_1, y_1), (x_2, y_2)$, then find the midpoint $(a,b)$ of the line segment joining them:

For the given example, $a=(1,0)$, $b=(0,1)$ and $c=(1,1)$. Then you would take the point $c/\sqrt{2}=\left(\frac{1}{\sqrt{2}},\frac{1}{\sqrt{2}}\right)$.

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Assign each line segment a parameter interval $[t_i, t_{i+}]$. So first step would be to look at $t$ and determine which interval applies e.g. $[t_3, t_4] = [0.75,1.00]$ and then do the interpolation on that segment.