A new approach to modelling the instantaneous cutting power in trochoidal machining and its practical application

Trochoidal machining could significantly improve cutting efficiency, enhance cutting stability, reduce cutting temperature, extend tool life, and reduce the cutting costs. However, in trochoidal machining, there are few studies focusing on modelling the instantaneous cutting power due to overlooking the importance of cutting temperature modelling. Also, instantaneous cutting power is an important basis for the optimization of trochoidal parameters and cutting parameters. In this work, we established a new and efficient method that could predict the instantaneous cutting power in trochoidal machining in high fidelity. First, the specific cutting energy of a given workpiece material, cutting tool, and cutting parameter in milling process was calibrated by cutting experiments. Second, the influence of the radial depth of cut on the specific cutting energy in milling process was quantitatively studied. Third, combining the obtained relationship between the specific cutting energy and radial depth of cut, the specific cutting energy curve in trochoidal machining was obtained. Then, a way to figure out the instantaneous material removal rate was proposed based on the acquired instantaneous 3D un-deform chip in trochoidal machining. Finally, based on the obtained specific cutting energy and instantaneous material removal rate, an accurate and efficient approach to predicting the instantaneous cutting power in trochoidal machining was proposed, and a practical application was demonstrated. The effectiveness of the proposed approach was validated by cutting experiments. The method proposed in this work could be adopted in cutting parameter optimization, tool-path optimization, and cutting temperature prediction in trochoidal machining.