Optimisation of tool path shape in trochoidal milling using B-spline curves

Abstract In recent years, trochoidal milling has become greatly widespread since it provides high productivity and long tool life, especially when cutting difficult-to-machine materials. Numerous studies have dealt with the analytical description and the experimental investigation of the evolution of cutting force, temperature, tool wear, chatter stability, etc. However, most of these analyses are focusing on the conventional circular and cycloid-shape trajectories. Only a few studies address the potential of improving the efficiency by modifying the tool path shape, leaving significant reserves untapped. If the mathematical formulation of the trajectory cannot be described easily, then a sophisticated optimisation algorithm is needed to determine the appropriate tool path shape. To overcome these difficulties at trochoidal milling of straight slots, the present work proposes a new tool path generation algorithm that can maximize the average material removal rate (MRR) while controlling the tool load. In this approach, the tool path is modelled by a B-spline curve whose control points are optimised using a differential evolution algorithm. The developed tool path generation strategy was compared through simulations and experiments with two widely used solutions viz the traditional cycloid-shaped tool path and a modern approach used in computer-aided manufacturing (CAM) systems. The results reveal that the developed method is able to control the tool load and the smoothness of the tool path, and most importantly, also exceeds the existing methods in terms of productivity.