Gosiger 3-D Application Engineer, Brian Stall (brian.stall@gosiger.com), explains that the advantages of trochoidal milling include improved tool life, reduced cycle time, increased material removal rates and the ability to use multi-fluted tools without the chips becoming welded onto the flutes.

Trochoidal millingcalculator

As early as 1964, when Republicans put forward Barry Goldwater as their presidential nominee, right-wing activists were at work hardening the conservative line.

Trochoidal millingSandvik

This CNC milling method is considered an excellent solution for difficult CNC machining situations including slotting of hardened and exotic materials such as Inconel or Titanium, and other materials where the slot is wider than the tool diameter. It also has application for milling deep pockets and grooves, and in confined cavities.

As defined by tool supplier Sandvik Coromant, trochoidal milling is “…circular milling that includes simultaneous forward movements. The cutter removes repeated slices of material in a sequence of continuous spiral tool paths in its radial direction.”

Trochoidal millingMastercam

This makes work hardening one of the most complex problems in science: it needs to be understood at many length scales, from the atomic-scale lengths of the dislocation cores, through the nano- and micrometre scales involved in dislocation interactions and structures, to the macroscale lengths associated with crack propagation and the structural stability of bulk materials.

“The other significant issue is that the CNC machine must not only have high speed capability, it must also be able to maintain continuous feed rates throughout the small, circular cutting motions. That’s why we recommend Okuma or Hardinge machines equipped with Okuma’s THINC OSP control. The OSP has the processing speed necessary to maintain speed and feed rates and properly control acceleration and deceleration.”

When the authors then deform them under the less-constrained conditions of a tensile or compressive test, structural relaxation sets in: the atomic packing increases and the volume introduced by the earlier deformation disappears; the number of STZs drops, causing the flow stress to increase; and work hardening is achieved.

Trochoidal millingFusion 360

Remarkably, the resulting material exhibits properties similar to those of conventional crystalline metals: it undergoes work hardening and does not form shear bands.

“We’ve done extensive work hardening our systems to prevent unauthorized access, and it was interesting to see how that hardening slowed us down as we tried to recover from an outage caused not by malicious activity but an error of our own making,” Mr. Janardhan wrote.

Have questions about trochoidal milling? Ask the experts at Gosiger today, and visit our YouTube channel to view video examples.

Trochoidal millingvs conventionalmilling

As Brian explains, “The keys to successful trochoidal milling are to maintain high speeds, keep the cutter in continuous movement and maintain low radial engagement. This method creates a chip thinning effect and reduces the number of axial passes because the tool cuts using the entire cutting flute length.”

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