Trokoid takım yollu frezeleme

As more attention is attracted to the quality and productivity in manufacturing,innovative strategies such as modifying toolpaths or applying feedrate scheduling havebeen alternates to the conventional machining methods. In this thesis an approach to themodeling of trochoidal milling, a widely used application in hard part machining, isproposed. In trochoidal milling the cutter traces a trochoidal toolpath and the radial depthof cut always varies along the toolpath. An analytical model for the engagement ofsimple surface machining is derived. Moreover, a numerical model is developed fordefining the engagement for complex surfaces containing hole or bosses on it. Lastly aforce model employing the engagement results is carried on for prediction of the cuttingforces. In order to maximize the efficiency in the trochoidal milling operation, differenttoolpath strategies are examined where the back half part of the planetary revolutionmotion is shortened with a linear motion or completely eliminated with double trochoidalmilling. Moreover, a forced based feedrate scheduling strategy is applied for doubletrochoidal milling for further maximization of machining efficiency. Physicalexperiments are performed in a three axis vertical machining center and the predictedforces are compared to the measured forces in three orthogonal directions. It is observedthat the predicted forces and the measured forces are in good agreement in all theapplications of the thesis. Finally an experimental study investigating the wearcomparison of trochoidal and linear milling with cutting forces and surface roughnessaspects is performed.Advisor: Dr. İsmail Lazoğlu Date: 20 October 2006Director: Prof. Dr. Süleyman Özekici