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High-Feed vs Trochoidal Strategies

In our previous blog, we discussed the importance of Tool rationalisation, the impact it can have and how to implement this on your shop floor.

Our engineers look at the manufacturing process from an end-to-end perspective, ensuring all the best solutions are offered. 

Once Tooling has been selected and rationalised, it’s then time to look at machining strategies, and the best ones to remove the most metal in the most efficient way.

Two of the most commonly seen strategies are High-feed milling and Trochoidal milling. Both are completely different strategies but offer high metal removal rates (MRR).

Here are some of the differences between them, as well as their benefits and disadvantages:

High-feed milling

Utilises a shallow depth of cut, but a high chip load (feed per tooth) increasing the feed rate, hence the name High Feed.  This method of machining aids in removing material quickly and efficiently, making it suitable for roughing operations.

Benefits

1.      Increased MMR because of its higher feed rates improving machine times.

2.     Reduced cutting forces minimising the load on the tool and machine tool, this can also reduce maintenance costs.

3.     Improved swarf evacuation because of the Tools design and high feed rates allowing for efficient swarf evacuation. This helps to reduce wear and recutting of swarf. 

Disadvantages

1.      Limited to roughing strategies as these types of Tools do not offer superior surface finishes needed for finishing strategies.

2.     Reduced Tool life because high cutting feeds and shallow depths of cut can lead to premature notching and wear.

Trochoidal milling

Trochoidal milling involves using the Tools cut length or flute length and utilising full depths of cut with a shallower stepover. This type of strategy is produced using CAM software, allowing the machine to mill in a continuous curved/circular motion rather than more traditional linear paths, ensuring the cutting load on the Tool is uniform.  It is commonly used for high-speed machining (RPM) and can help with finishing operations.

Benefits

1.      The naturally curved toolpath is kinder on the Tool - allowing for a more gradual engagement with the material - which increases Tool life.

2.     The Tools engagement with the material is smooth and has a continuous Tool load, leading to reduced vibrations and improved surface finish.

3.     A trochoidal toolpath reduces the chances of Tool marks or chatter, resulting in a smoother surface finish.

Disadvantages

1.      Trochoidal milling uses multiple passes to remove material, this extends the overall machining time compared to a high-feed milling strategy.

2.     Generating the trochoidal toolpath requires more complex programming compared to traditional linear paths, increasing setup time.

When to use each strategy?

High-feed milling should be used when high material removal is required, and is primarily used for roughing operations. It is suitable for, but not limited to, softer materials and where surface finish is not critical.

Trochoidal milling lends itself to the roughing of 2D features but not limited to this. It is also great for higher RPM lower torque machines whilst maximising on the increased MRR. Finally, it’s good when needing to reduce vibrations in the Tools and components whilst maintaining a decent surface finish. 

Final thought…

Ultimately, the choice between High-feed milling and Trochoidal milling depends on the specific application, material, desired finish, and available machining capabilities. Both have pros and con’s, but as always in the manufacturing world it’s all down to the components being machined, your set-up, and time allocated on the job.