A new trochoidal milling strategy for high-performance CNC machining

Abstract

This article introduces a novel adaptive trochoidal tool path strategy for high-performance CNC milling. A dynamic, parametric tool path model is developed to continuously adjust the stepover based on tool diameter, flute count, and feed rate, enabling real-time modulation of cutter engagement. This adaptive stepover approach significantly reduces force fluctuations and minimizes sudden load variations. As a key contribution, a custom G-code is developed to eliminate non-cutting tool path segments, enabling the creation of compact and efficient trajectories. Two strategies were evaluated: Strategy 1 uses conventional G02 interpolation, while Strategy 2 incorporates both G02 and G03 commands along with stepover modulation to optimize tool path efficiency. Force modelling, calibrated through full-immersion slot milling on aerospace grade Al7050, accurately predicted cutting forces along curved paths, with simulation errors of less than 6%. The experimental results confirmed that the implementation of Strategy 2 significantly mitigated the cutting load, leading to reductions of approximately 50% in total cutting force, 26% in maximum torque, and power consumption relative to conventional slot milling. Additionally, it shortened tool path length and machining time by 33% relative to Strategy 1. These results demonstrate the effectiveness of the proposed strategy in achieving load-aware and supporting more intelligent and sustainable CNC machining for advanced manufacturing applications. © 2025 The Society of Manufacturing Engineers