Epicycloidal Versus Trochoidal Milling-Comparison of Cutting Force, Tool Tip Vibration, and Machining Cycle Time

Salehi, Mehdi; Blum, Michelle; Fath, B.; Akyol, T.; Haas, R.; Ovtcharova, Jivka

doi:10.1016/j.procir.2016.04.001

Cited by 22 publications

(11 citation statements)

References 7 publications

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“…The motion of the trochoidal path can be described as a superposition of a circular motion with a linear movement of the tool. In literature, different approaches for the calculation of trochoidal path were compared, e.g., a circular and trochoidal model by Rauch et al [23] or the epicycloidal model by Salehi et al [24]. In this paper, the calculation of X-and Y-coordinates of the tool center point along the path is given by with a tool diameter D = 16 mm , the step over S o = 1 mm and the path angle .…”

Section: Calculation Of Trochoidal Pathsmentioning

confidence: 99%

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Bergmann

Potthoff

Rickhoff

et al. 2021

Prod. Eng. Res. Devel.

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The aerospace industry utilizes nickel-based super-alloys due to its high level of strength and corrosion resistance. To evaluate milling strategies regarding tool wear, the prediction of forces during these cutting operations is essential. This comprises the determination of the undeformed chip thickness. Due to the complex interdependencies of tool engagements, the determination of these thicknesses is challenging. A geometric physically-based simulation system was extended by a novel time-discrete envelope model to increase the precision of the calculated undeformed chip thicknesses. In order to take tool wear into account, digitized topographies of cutting inserts in different states of tool wear were modelled.

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Section: Calculation Of Trochoidal Pathsmentioning

confidence: 99%

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Bergmann

Potthoff

Rickhoff

et al. 2021

Prod. Eng. Res. Devel.

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“…The tool path is typically circular, but there are other developed types, such as true trochoidal, elliptical, etc., to improve the process efficiency. [1][2][3] Since the tool diameter is less than the slot width, the engagement angle between tool and workpiece is lower as compared to that of conventional milling. Therefore, cutting forces, cutting temperature, and tool wear are lower.…”

Section: Introductionmentioning

confidence: 99%

“…22 Salehi et al improved the material removal rate by 20% on using a developed epicycloidal tool path at the expense of a 10% increase in the forces. 2 However, it has been proved that dynamic trochoidal milling and variable feed trochoidal milling are better than the static one, 23,24 but high-dynamic machine tools are required. Adaptive trochoidal milling with a variable step or a variable trochoidal radius showed its capability to stabilize the cutting forces along the tool path, consequently, the material rate has been improved.…”

Section: Introductionmentioning

confidence: 99%

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Wagih,

Hassan,

El-Hofy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Trochoidal milling has been developed to enhance tool life during slot machining. It is characterized by reduced cutting forces, cutting temperature, and tool wear as compared to conventional milling processes. It is effective in machining difficult-to-cut materials, high-speed machining, and groove corners. However, this process has not been deeply investigated enough to discover its advantages and optimize its parameters. A full factorial design of 144 experiments has been applied in this paper to investigate extensively the effects of axial depth of cut, feed rate, and trochoidal step on material removal rate, cutting forces, and specific energy in trochoidal milling. Trochoidal step and axial depth of cut almost have the same contributions on cutting forces by 32% and 31% respectively, followed by feed rate by 25%. Feed rate, trochoidal step, and axial depth of cut influence the material removal rate by 37%, 30%, and by 19% respectively. The contributions of feed rate, trochoidal step, and axial depth of cut on relative specific energy are 57%, 24%, and 8% respectively. The increase of axial depth of cut increases the maximum resultant force till a threshold value, then it stabilizes. This behavior occurred due to the increase of the maximum engagement angle to a certain limit, then it does not increase any more. Both feed rate and trochoidal step linear affect maximum resultant force and material removal rate, while the relationships are non-linear for specific energy. It is recommended to machine slots in full depth with the highest possible trochoidal step and feed rate, considering the increase of tool wear and surface roughness. It is preferred to use a cutting tool of a large helix angle and small diameter to reduce the threshold axial depth of cut. Overall, this study is significant in characterizing, designing, and optimizing of trochoidal milling through experimental work.

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“…They found that the abrupt increasing of radial depth of cut was avoided, which made trochoidal milling advantageous in high speed machining. Salehi et al [12] employed epicycloidal path to improve the trochoidal cutting efficiency. Simulations and experiments showed that the cutting time could be effectively reduced with little cutting load increase.…”

Section: Introductionmentioning

confidence: 99%

An Analytical Approach to Cutter Edge Temperature Prediction in Milling and Its Application to Trochoidal Milling

Deng

Chen

et al. 2020

Applied Sciences

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Cutter edge temperature in milling is an important factor to cutter life. With high cutting speed and feedrate, the cutting efficiency is high; however, the cutter edge temperature is high, shortening the cutter life. Therefore, it is necessary to know the cutter edge temperature in milling. Unfortunately, the cutter edge temperature is difficult to measure and predict in milling. To address the technical challenge, an analytical approach was proposed to predict cutter edge temperature in milling. First, the heat flux into the cutter edge was calculated. Second, by using the Green function, the cutter edge temperature was figured out, and the results obtained from this approach agreed well with that of a recognized test. Then, based on the engagement between the cutter and workpiece in trochoidal milling, the cutter edge temperature was obtained in trochoidal milling. Finally, a temperature comparison was made between trochoidal and side milling based on this analytical approach, and the reasons that trochoidal machining could extend the cutter life were found. This approach is first proposed to calculate the cutter edge temperature in trochoidal milling and can be applied to machining parameters optimization in trochoidal milling and cutter design optimization.

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Epicycloidal Versus Trochoidal Milling-Comparison of Cutting Force, Tool Tip Vibration, and Machining Cycle Time

Cited by 22 publications

References 7 publications

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

An Analytical Approach to Cutter Edge Temperature Prediction in Milling and Its Application to Trochoidal Milling

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