Epicycloidal versus trochoidal milling- Comparison of cutting force, tool tip vibration, and machining cycle time

Among several strategies for high performance cutting, trochoidal milling is an efficient one for roughing process and reduces the cycle times significantly. For maximization of the efficiency and reducing the machining cycle time in the trochoidal milling, a novel tool path strategy, so-called, epicycloidal milling is developed. In this paper, mathematical model of the epicycloidal milling is presented. For the two mentioned strategies, comparison between cutting forces, tool tip vibrations, and machining cycle times are performed by four levels of machining experiments. To calculate the tool tip vibration, modal parameters of machine tool are achieved by system identification and then dynamic models of the machine spindle has been developed. It is observed that epicycloidal milling can improve machining cycle time, while the measured forces and calculated vibrations increased slightly. (C) 2016 The Authors. Published by Elsevier B.V