Influence of the Trochoidal Tool Path Generation Method on the Milling Process Efficiency

Waszczuk, Kamil

doi:10.12913/22998624/122198

Cited by 6 publications

(5 citation statements)

References 4 publications

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“…At present, the milling machine may not reach the programmed parameters to accelerate the drive lead screw because the tool path is too short [19]. The smaller the radius of the arcs forming the tool movement trajectories, the farther the actual feed speed values may be from the programmed parameters value in case of processing with a larger feed speed.…”

Section: Resultsmentioning

confidence: 99%

“…In this method, NC tool paths are optimized along the feed direction of the tool path without the consideration of the consistency in the crossing direction. Through analyzing the relationship between cutting parameters and feed speed in cycloidal milling, Waszczuk [19] found that the actual feed speed of the machine tool is far away from the set feed speed in case of using the recommended parameters by the tool manufacturer. Moreover, the greater the curvature of the tool path, the farther the actual feed speed of the machine tool is far away from the set value.…”

Section: Fig 1 Tool Path Based On the Circle Model And The Trochoidal...mentioning

confidence: 99%

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An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Han,

Gu,

et al. 2023

Int J Adv Manuf Technol

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The machining time is mainly related to the tool path and the corresponding feed speed, while the trochoidal tool path depends on the trochoidal step and trochoidal radius. The material removal rate is periodically distributed along the tool path in trochoidal milling a hole. But more than half of tool paths do not cut material in trochoidal milling a hole, so a constant feed speed in milling a hole will limit the machining efficiency. In this paper, a trochoidal radius optimization approach is presented to improve the efficiency of trochoidal milling a hole, which considering the optimal feed speed. Firstly, the mathematical representation of the trochoidal radius is formulated by analyzing the generation principle of trochoidal path, so the trochoidal radius could be determined under the premise of the hole diameter, maximum uncut radial material and the tool diameter are fixed. Furthermore, the trochoidal radius optimization model， which based on the adjusted feed speed, is established with the goal of minimizing the machining time. Secondly, an adaptive feed speed scheduling strategy for trochoidal milling is proposed, which is constrained by stable material removal rate and adjusted by a cubic polynomial algorithm. Finally, taking a hole machining as an example, simulation and experimental results show that the efficiency of applying the trochoid milling method proposed has increased by 13.8% compared to traditional helix milling method.

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Section: Resultsmentioning

confidence: 99%

Section: Fig 1 Tool Path Based On the Circle Model And The Trochoidal...mentioning

confidence: 99%

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Han,

Gu,

et al. 2023

Int J Adv Manuf Technol

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“…They observed that the true trochoidal path gave the best surface quality slightly followed by the circular-type trochoidal path, then the stretched path, and finally the semi-circular one. In later research, K. Waszczuk obtained different results; the circular-linear path was the best of them [33]. Contrary to the formerly mentioned, walls roughness is larger than that of bottom roughness, except for the third path type.…”

Section: Fig 1 Schematic Drawing Of the Trochoidal Milling Processmentioning

confidence: 90%

“…Contrary to the formerly mentioned, walls roughness is larger than that of bottom roughness, except for the third path type. However its significance, waviness of the produced slots has been mentioned in a few articles such as [4,29,33,34] as observation and has not been investigated with the machining parameters. Wagih et al developed a new path to reduce the slot waviness and surface roughness using a linear-elliptical tool path [19].…”

Section: Fig 1 Schematic Drawing Of the Trochoidal Milling Processmentioning

confidence: 99%

Investigating the effects of trochoidal milling parameters on the waviness and surface roughness of P20 alloy steel slots: Analytical and Experimental

Wagih,

Maher,

Hassan

2023

Preprint

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This paper aims to study, analytically and experimentally, the effects of trochoidal milling parameters on the waviness and the surface roughness of P20 alloy steel slots. The considered process parameters in this paper are the axial depth of cut, trochoidal step, and feed rate, in addition to the slot width. A geometrical analytical model of the tool cutting edges imprints has been developed to explain the of waviness and surface roughness at the slot walls and bottom. Results of this model proved that increasing the slot width significantly reduces the slot walls waviness, while increasing the feed rate or the trochoidal step increases the waviness of the slot left and right walls respectively. The experimental results proved that the axial depth of cut has not a significant effect on the slot walls waviness, and the tool edges imprints have the greatest effect on the bottom surface roughness. The surface roughness of the slot bottom decreases from left to right. Moreover, increasing the feed rate significantly increased the bottom surface roughness by 25%, 29%, and 29% at the left wall, middle, and right wall of the machined slot, respectively. However, increasing the axial depth of cut, significantly increased the bottom surface roughness only at the left wall and the middle of the machined slot by 11% and 19%, respectively. Experimental and analytical results of waviness and surface roughness were in good agreements which verifies the potential of using the developed model to predict the slot surface texture during circular trochoidal milling.

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“…Other researchers proved that tool path considerably affects cutting forces. 1,2,32 Specific energy, U, is being employed to evaluate the process efficiency. 6,19 It can be defined as the consumed energy, E, to remove a unit volume of work material, MRV, or the ratio between cutting power, P, to material removal rate, MRR, equation (1).…”

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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Influence of the Trochoidal Tool Path Generation Method on the Milling Process Efficiency

Cited by 6 publications

References 4 publications

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Investigating the effects of trochoidal milling parameters on the waviness and surface roughness of P20 alloy steel slots: Analytical and Experimental

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

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