Trochoidal milling

In this paper, an approach to the modeling of trochoidal milling is proposed. An analytical model for defining the engagement is derived and a force model depending on the engagement is employed for the prediction of the cutting forces. In order to handle more complex part geometries, in addition to the analytical model, a numerical engagement model is developed. With the numerical model, any surface with holes, bosses, etc. can be handled. Moreover, for the maximization of the efficiency in the trochoidal milling operation, a different tool path strategy (double trochoidal milling) is examined. Physical experiments are performed in a three-axis vertical machining center and the predicted forces are compared with the measured forces. It is observed that the predicted forces and the measured forces are in good agreement in all the applications of the study.