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

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Abstract

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 considers 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 is 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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Funding

This work was supported by the Opening Topic Fund of Key Laboratory of Aeroengine High Performance Manufacturing Industry and Information Technology of Ministry of China (HPM-2020–04), the Coal Joint Fund Project of Shaanxi (2019JLM-37), and the Shaanxi Provincial Innovation Talent Promotion Plan—Science and Technology Innovation Team (2021TD-27).

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Authors and Affiliations

  1. Xi’an University of Science and Technology, Xi’an, 710054, China

    Fei-Yan Han, Zhi-Cheng Gu, Long-Long He, Tian-Mao Gou, Chuan-Wei Zhang & Man-Zhi Yang

  2. Xi’an Coal Mine Machinery Co., Ltd, Xi’an, 710005, China

    Ren-Gui Shi

Authors
  1. Fei-Yan Han
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  2. Zhi-Cheng Gu
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  3. Long-Long He
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  4. Tian-Mao Gou
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  5. Chuan-Wei Zhang
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  6. Man-Zhi Yang
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  7. Ren-Gui Shi
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Contributions

FYH: writing—review and editing, methodology, investigation, supervision, conceptualization. ZCG: writing—original draft, writing—review and editing, software, validation, data collection and analysis. LLH: writing—review and editing, software, validation, methodology, data collection and analysis. TMG: data curation, validation, data collection and analysis. CWZ: investigation, supervision, writing—review and editing. MZY: investigation, data curation.

RGS: validation, material preparation.

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Correspondence to Fei-Yan Han.

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Han, FY., Gu, ZC., He, LL. et al. An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling. Int J Adv Manuf Technol 130, 1527–1539 (2024). https://doi.org/10.1007/s00170-023-12804-0

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  • DOI: https://doi.org/10.1007/s00170-023-12804-0

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