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 experimental investigation of evolution force, temperature, wear, chatter stability, etc. However, most these analyses are focusing on conventional circular cycloid-shape trajectories. Only a few address potential improving efficiency by modifying path shape, leaving significant reserves untapped. If mathematical formulation trajectory cannot be described easily, then sophisticated optimisation algorithm is needed to determine appropriate shape. To overcome difficulties at straight slots, present work proposes new generation that can maximize average material removal rate (MRR) while controlling load. this approach, modelled B-spline curve whose control points optimised using differential algorithm. The developed strategy was compared through simulations experiments two widely used solutions viz traditional cycloid-shaped modern approach in computer-aided manufacturing (CAM) systems. results reveal method able load smoothness path, importantly, also exceeds existing methods terms productivity.