Meantime his comrades were journeying on, till on a sudden one of them stumbled against something. "What can that be?" said the other. They looked, and could think of nothing that it was like but a nose. "We will follow it and find its owner, however," said they. So they traced it up, till at last they found their poor comrade, lying stretched along under the apple-tree.

Distance between the passes of the toolpath; the path spacing. The distance the tool will move horizontally when making the next pass. Too great of a step-over will cause difficulty machining because there will be too much pressure on the tool as it is trying to cut with too much of its surface area.

Poor fellows! they began to think what was now to be done. "Comrades," at last said the second soldier, who had had the purse, "we had better part; we cannot live together, let each seek his bread as well as he can." So he turned to the right, and the other two went to the left, for they said they would rather travel together. Then on the second soldier strayed till he came to a wood (now this was the same wood where they had met with so much good luck before), and he walked on a long time till evening began to fall, when he sat down tired beneath a tree, and soon fell asleep.

Milling cutter held by its shank that cuts on its periphery and, if so configured, on its free end. Takes a variety of shapes (single- and double-end, roughing, ballnose and cup-end) and sizes (stub, medium, long and extra-long). Also comes with differing numbers of flutes.

One cutting tool manufacturer that comes to mind is FRAISA in Minnesota. With their HX-RNVS and their XSpeed-H high-speed tools, they can accommodate a wide range of applications from mold steel to high-hardened steel. Some of these tools incorporate more cutting edges (Z6 and Z8) and depth-of-cut up to 5XD (e.g., 10mm dia. 50mm cutting depth). This is due to the small size of the chip created and thus these types of tools can push even higher feed rates due to an increase in teeth.

All this was very well for a time, but they found it would not do to stay at home always; so they got together all their rich clothes, and jewels, and money, and ordered their coach with three dapple-grey horses, and set out on a journey to see a neighbouring king. Now this king had an only daughter, and as he saw the three soldiers travelling in such grand style, he took them for kings' sons, and so gave them a kind welcome. One day, as the second soldier was walking with the princess, she saw that he had the wonderful purse in his hand. Then she asked him what it was, and he was foolish enough to tell her,—though, indeed, it did not much signify what he said, for she was a fairy, and knew all the wonderful things that the three soldiers brought. Now this princess was very cunning and artful; so she set to work and made a purse, so like the soldier's that no one would know one from the other; and then she asked him to come and see her, and made him drink some wine that she had got ready for him, and which soon made him fall fast asleep. Then she felt in his pocket, and took away the wonderful purse, and left the one she had made in its place.

In the morning each told his story, and showed the gift he had got from the elf: and as they all liked each other very much, and were old friends, they agreed to travel together to see the world, and, for a while, only to make use of the wonderful purse. And thus they spent their time very joyously; till at last they began to be tired ​of this roving life, and thought they should like to have a home of their own. So the first soldier put his old cloak on, and wished for a fine castle. In a moment it stood before their eyes: fine gardens and green lawns spread round it, and flocks of sheep, and goats, and herds of oxen were grazing about; and out of the gate came a grand coach with three dapple-grey horses, to meet them and bring them home.

Due to the ongoing improvements in machine motion control, CAM systems, and the design of simple, easy-to-use Trochoidal Cycles available at many controls, it is worth looking into its practices for a long roughing routine or for tough, hard-to-machine materials.

For more information on trochoidal milling and other features of the Heidenhain TNC control, or to sign up for online or in-person classes, click here.

Another similar type of toolpath motion that also reaps many of the benefits we will discuss is a peel-type toolpath. These toolpaths typically have an arc-in-path followed by a straight line or a line that follows the contour shape followed by an arc-out-path. There are specific parameters that generally describe a peel-type toolpath. Typically, it is around a maximum of 10% tool engagement with a maximum Z depth and higher feed rates between the transition moves. There is also a reduced feed rate upon entry to maintain the appropriate relationship in feed-per-tooth between the center of the cutter and the outside cutting edge upon engagement.

Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

Then they thanked their old friend very heartily for all his kindness; and it was agreed that the poor soldier, who had already tried the power of the apple, should undertake the task. So he dressed himself up as a gardener's boy, and went to the king's palace, and said he had apples to sell, so fine and so beautiful as were never seen there before. Every one that saw them was delighted, and wanted to taste; but he said they were only for the princess; and she soon sent her maid to buy his stock. They were so ripe and rosy that she soon began eating; and had not eaten above a dozen before she too began to wonder what ailed her nose, for it grew and grew down to the ground, out at the window, and over the garden, and away, nobody knows where.

What was to be done? They tried to carry him, but in vain. They caught an ass that was passing, and raised him upon its back; but it was soon tired of carrying such a load. So they sat down in despair, when before long up came their old friend the dwarf with the red jacket. "Why, how now, friend?" said he, laughing: "well, I must find a cure for you, I see." So he told them to gather a pear from another tree that grew close by, and the nose would come right again. No time was lost; and the nose was soon brought to its proper size, to the poor soldier's Joy.

A few other materials that can benefit from trochoidal style machining operations include hardened tool steel and any material that is work or case hardened or abrasive as these types of materials often exhibit chipping along the flutes.

Then the third soldier's turn to watch came; and he also had little Red-jacket for his guest, who gave him a wonderful horn, that drew crowds around it whenever it was played, and made every one forget his business to come and dance to its beautiful music.

Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

In closing, trochoidal/peel mill style techniques are well proven to save time and tool life in machining operations. If you are not yet using them, I encourage you to investigate this possibility on your existing equipment if it can handle fast and accurate requirements or on your next purchase.

To increase productivity further with trochoidal milling techniques, the user can adapt the spindle load by monitoring the feed rate. To monitor this, Heidenhain offers a control option AFC (adaptive feed control). This monitors spindle load and allows the user to control the feed rate with input parameters. Users can also adjust the sensitivity of this feed rate.

With Heidenhain’s latest generation of NC software, the company now has the capability to rough a part with trochoidal movements using its newest and latest OCM (optimized contour roughing) cycle. This is an option for the TNC Controls. With these cycles, a user can rough a 2D contour, and finish walls and floors if needed.

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This factor depends on the relationship or ratio between ae (the working engagement) and (diameter of the cutter) D. This can result in anywhere between a 10-15% increase in MRR (metal removal rate) for that particular operation over conventional methods.

Then he thought to himself, "I must frighten this cunning princess a little more before I shall get what I want from her"; so he gave her another doze of the apple, and said he would call on the morrow. The morrow came, and the nose was ten times as bad as before. "My good lady," said the doctor, "something works against my medicine, and is too strong for it; but I know by the force of my art what it is: you have stolen goods about you, I am sure; and if you do not give them back, I can do nothing for you." But the princess denied very stoutly that she had anything of the kind. "Very well," said the doctor, "you may do as you please, but I am sure I am right, and you will die if you do not own it." Then he went to the king, and told him how the matter stood. "Daughter," said he, "send back the cloak, the purse, and the horn, that you stole from the right owners."

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Therefore, for smaller tools, AFC can help prevent chipping in exotic metals. These adjustments can help prevent load up on the teeth even for a few split seconds that can prevent a reduction in tool life.

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With low radial engagement and utilizing as much of the flute length as possible, the machining operation will also generate lower cutting forces. This helps the machining process, in turn, by creating less vibration and load on the spindle bearings and a stable operation. Heat and vibration are two of the biggest problems when cutting exotic hard-to-cut materials.

Many CAM companies have been incorporating trochoidal style roughing techniques for many years now and this is sure to continue in the smaller CAM packages. More control companies are expected to expand their cycles to include trochoidal style toolpaths, therefore for simple parts or that simple job, a program can be created on the control with little time if a 3D model or CAM package is not available.

In the morning she began to ramble about, singing ballads so beautifully that all the tents were left empty, and the soldiers ran round in crowds, and thought of nothing but hearing her sing. Amongst the rest came the soldier to whom the horn belonged, and as soon as she saw him she winked to her maid, who slipped slily through the crowd, and went into his tent where it hung, and stole it away. This done, they both got safely back to the palace, the besieging army went away, the three wonderful gifts were all left in the hands of the princess, and the three soldiers were as penniless and forlorn as when little Red-jacket found them in the wood.

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Then the king made known to all his kingdom, that whoever would heal her of this dreadful disease should be richly rewarded. Many tried, but the princess got no relief. And now the old soldier dressed himself up very sprucely as a doctor, and said he could cure her. So he chopped up some of the apple, and, to punish her a little more, gave her a doze, saying he would call to-morrow and see her again. The morrow came, and, of course, instead of being better, the nose had been growing on all night as before; and the poor princess was in a dreadful fright. So the doctor then chopped up a very little of the pear and gave her, and said he was sure that would do good, and he would call again the next day. Next day came, and the nose was to be sure a little ​smaller, but yet it was bigger than when the doctor first began to meddle with it.

If you have a newer machine, find the operations where you may be able to try these techniques, then find the right tool, hold it preferably in a hydraulic or shrink fit holder, and experiment with trochoidal techniques available on your control or in your CAM system.

Substance used for grinding, honing, lapping, superfinishing and polishing. Examples include garnet, emery, corundum, silicon carbide, cubic boron nitride and diamond in various grit sizes.

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The second soldier's turn to watch soon came, and the first laid him down to sleep; but the second man had not sat by himself long before up came the dwarf in the red jacket again. The soldier treated him in as friendly a way as his comrade had done, and the little man gave him a purse, which he told him would be always full of gold, let him draw as much as he would out of it.

They had journeyed on a long way, sick at heart with their bad luck at thus being turned loose on the world in their old days; when one evening they reached a deep gloomy wood, through which lay their road. Night came fast upon them, and they found that they must, however unwillingly, sleep in this wood; so, to make all as safe as they could, it was agreed that two should lie down and sleep, while a third sat up and watched, lest wild beasts should break in and tear them to pieces. When he was tired he was to wake one of the others, and sleep in his turn; and so on with the third, so as to share the work fairly among them.

Morning dawned, and he was greatly delighted, at opening his eyes, to see that the tree was laden with the most beautiful apples. He was hungry enough, so he ​soon plucked and ate first one, then a second, then a third apple. A strange feeling came over his nose: when he put the apple to his mouth something was in the way. He felt it—it was his nose, that grew and grew till it hung down to his breast. It did not stop there—still it grew and grew. "Heavens!" thought he, "When will it have done growing?" And well might he ask, for by this time it reached the ground as he sat on the grass,—and thus it kept creeping on, till he could not bear its weight or raise himself up; and it seemed as if it would never end, for already it stretched its enormous length all through the wood, over hill and dale.

Any controlled equipment that allows an operator to program its movement by entering a series of coded numbers and symbols. See CNC, computer numerical control; DNC, direct numerical control.

Trochoidal milling has become a popular technique to utilize in slotting, pocketing, roughing, and machining of hard materials found in aerospace components such as titanium and Inconel where the chips are typically hard to break.

But the soldier stood looking at her too long; for she turned round, and the moment she saw him she started up and cried out with all her force, "Thieves! thieves!" so that the whole court came running in, and tried to seize on him. The poor soldier now began to be dreadfully frightened in his turn, and thought it was high time to make the best of his way off; so, without thinking of the ready way of travelling that his cloak gave him, he ran to the window, opened it, and jumped out; and unluckily, in his haste, his cloak caught and was left hanging, to the great joy of the princess, who knew its worth.

In the coming years, more tooling companies will expand their line to include HSM or high-speed machining tools that are especially useful during trochoidal milling operations.

​The two who were to rest first soon lay down and fell fast asleep; and the other made himself a good fire under the trees, and sat down by its side to keep watch. He had not sat long before, all on a sudden, up came a little dwarf in a red jacket. "Who is there?" said he. "A friend," said the soldier. "What sort of a friend?" "An old broken soldier," said the other, "with his two comrades, who have nothing left to live on; come, sit down and warm yourself." "Well, my worthy fellow," said the little man, "I will do what I can for you; take this and show it to your comrades in the morning." So he took out an old cloak and gave it to the soldier; telling him, that whenever he put it over his shoulders anything that he wished for would be done for him. Then the little man made him a bow and walked away.

So, in performing large depth of cuts with shallow step-overs, operators using trochoidal milling can utilize the entire tool for much of its life. This, in turn, generates lower cutting forces with chip thinning principles that create a better outcome by enhancing productivity and tool longevity.

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Also do not underestimate the importance of a good motion control system or high-speed mode in your machine tool. For trochoidal milling to be effective, the machine used must be able to accelerate and fast and quite accurately to maintain the appropriate tolerance on the contour path.

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If the machine cannot hold tolerance, then the user may find that trochoidal milling techniques are causing gouges in part corners where the tool picks out material at a high rate of speed and where the acceleration/deceleration is at its greatest.

Did you ever hear the story of the three poor soldiers, who, after having fought hard in the wars, set out on their road home, begging their way as they went?

Imagine a satellite orbiting the earth at a constant height. If one were to apply a large enough force perpendicular to its orbital path to force it back to earth, it would exhibit a type of circular path. With each revolution, its rate of travel or pitch in this orbital path is its trochoidal movement. A circular motion with a low radial engagement and constant step-over (feed per tooth) is the best way to describe trochoidal motion.

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Trochoidal milling has been around for quite some time. Many in the industry have seen direct positive impacts on tool longevity and higher removal rates (MRR) by utilizing its fundamentals. Conventional machining methods are out of date in many situations.

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Machining, normally milling, that creates slots, grooves and similar recesses in workpieces, including T-slots and dovetails.

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Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.

​into his daughter's chamber and talked with her; but she said, "Let me try first if I cannot beat them some way or another." So she thought of a cunning scheme to overreach them; and dressing herself out as a poor girl, with a basket on her arm, she set out by night with her maid, and went into the enemy's camp, as if she wanted to sell trinkets.

The next morning the soldiers set out home; and soon after they reached their castle, happening to want some money, they went to their purse for it, and found something indeed in it; but to their great sorrow, when they ​had emptied it, none came in the place of what they took. Then the cheat was soon found out; for the second soldier knew where he had been, and how he had told the story to the princess, and he guessed that she had played him a trick. "Alas!" cried he, "poor wretches that we are, what shall we do?" "Oh!" said the first soldier, "let no grey hairs grow for this mishap: I will soon get the purse back." So he threw his cloak across his shoulders, and wished himself in the princess's chamber.

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Chip thickness principles depend on the type of tool being used such as 90-, 45- or 10-degree cutting angle, and whether the user is peripheral or face milling. If performing periphery milling or side milling for a peel style operation with a standard flat endmill (90-degree edge), a factor or coefficient can be applied that will affect and increase the feed per tooth and thus maintain the same chip thickness as in a conventional machining process.

Then she ordered her maid to fetch all three, and gave them to the doctor, and begged him to give them back to the soldiers; and the moment he had them safe he gave her a whole pear to eat, and the nose came right. And as for the doctor, he put on the cloak, wished the king and all his court a good day, and was soon with his two brothers; who lived from that time happily at home in their palace, except when they took an airing to see the world, in their coach with the three dapple-grey horses.

With Peel or trochoidal style operations, the machine operator can cut more challenging materials such as titanium and Inconel that are commonly found in aerospace components and castings. It is very advantageous when cutting high-strength aerospace alloys to use these types of methods when possible because typical machining of these alloys, is often difficult to break the chip.

The advantages of low radial engagement in trochoidal milling create a reduced chip thickness that reduces the load on the tool, a positive byproduct of this strategy. A reduced deflection provides closer to nominal stock allowance in all areas of the contour. This helps to ensure the tool is removing the same amount of stock when finishing the surfaces, which will ensure uniform surface finish quality or integrity. Low radial engagement’s big advantage lowers the temperature at the cutting zone, which provides a less thermal load on the tool. This creates better predictability in a process and simultaneously provides better tool life.

Trochoidal milling techniques create superior chip removal, especially when M8 or air blast accompanies. Therefore, the possibility of having to re-cut chips is reduced. Uniform tool engagement both radially and axially is also a benefit of using these strategies. This translates to uniform wear along the cutting edges and also keeps the tool sharper longer due to the small radial engagement strategies created by the control or CAM system. Higher cutting parameters are also possible. This is because of chip thickness principles.

"I will do something more for you yet," said the dwarf; "take some of those pears and apples with you; whoever eats one of the apples will have his nose grow ​like yours just now; but if you give him a pear, all will come right again. Go to the princess, and get her to eat some of your apples; her nose will grow twenty times as long as yours did: then look sharp, and you will get what you want from her."

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