Trochoidal milling has been developed to extend the cutting tool life as compared to conventional milling. It is widely used in the machining of slots and corners of molds and dies. There are several tool paths typically used in trochoidal milling such as true, circular, variable-feed, and variable-step trochoidal tool paths. However, these paths suffer from low material removal rates, low surface qualities, high CPU processing times, and/or the requirement of high-dynamic machine tools. Elliptical trochoidal tool path showed its capability to improve the material removal rate, but the expected low surface quality of the produced slot. In this paper, the elliptical tool path will be analyzed analytically and experimentally. The effect of elliptical tool path on material removal rate, cutting forces, walls waviness, and surface roughness have been investigated. A novel linear elliptical-based tool path has been proposed to enhance the elliptical tool path performance by improving both material removal rate and surface quality. A Performance index has been utilized to evaluate the performance of these processes. An analytical model for the local maximum chip thickness in elliptical tool path has been conducted to correlate this path with the cutting forces. The slot walls waviness has been modeled based on the cutting tool path geometry and validated experimentally with error less than 11%. The experimental results showed that the elliptical tool path improved the material removal rate by 11%, with a slight reduction in the maximum resultant cutting force by 3%. On the other hand, the walls waviness and surface roughness have been increased by 45% and 38% respectively as compared to the typical true trochoidal tool path. The introduction of linear paths at the elliptical path sides in the linear-elliptical tool path improved the performance index about 18 times by improving the material removal rate, waviness, and surface quality by 5%, 300%, and 74% respectively, without a significant effect on cutting forces. Therefore, the novel linear-elliptical paths are promising tool paths in increasing the performance of trochoidal milling due to the improved material removal rate, walls waviness, and surface quality, without a significant effect on cutting forces, which will improve the process machinability and cost-effectiveness.

与传统铣削相比，摆线铣削的开发是为了延长切削刀具的使用寿命。广泛应用于模具的槽、角部加工。摆线铣削中通常使用多种刀具路径，例如真实刀具路径、圆形刀具路径、可变进给刀具路径和可变步长摆线刀具路径。然而，这些路径面临材料去除率低、表面质量低、CPU 处理时间长和/或高动态机床要求的问题。椭圆摆线刀具路径显示了其提高材料去除率的能力，但所生产的槽的​​预期表面质量较低。本文将对椭圆刀具路径进行分析和实验分析。研究了椭圆刀具路径对材料去除率、切削力、壁波纹度和表面粗糙度的影响。提出了一种新颖的基于线性椭圆的刀具路径，通过提高材料去除率和表面质量来增强椭圆刀具路径的性能。绩效指数已用于评估这些流程的绩效。我们建立了椭圆刀具路径中局部最大切屑厚度的分析模型，将该路径与切削力相关联。槽壁波纹度已根据切削刀具路径几何形状进行建模，并经过实验验证，误差小于 11%。实验结果表明，椭圆形刀具路径将材料去除率提高了11%，最大合成切削力略微降低了3%。另一方面，与典型的真正摆线刀具路径相比，壁波纹度和表面粗糙度分别增加了 45% 和 38%。在直线-椭圆刀具路径的椭圆路径侧引入直线路径，材料去除率、波纹度和表面质量分别提高了5%、300%和74%，性能指标提高了约18倍，而无需对切​​削力影响显着。因此，新颖的线性椭圆路径是提高摆线铣削性能的有前途的刀具路径，因为它提高了材料去除率、壁波纹度和表面质量，而且对切削力没有显着影响，这将提高工艺的可加工性和成本-效力。