Modeling of Turn-milling Process

This paper presents an analytical approach for modeling of turn-milling which is a promising cutting process combining two conventional machining operations; turning and milling. This relatively new technology could be an alternative to turning for improved productivity in many applications but especially in cases involving hard-to-machine material or large work diameter. Intermittent nature of the process reduces forces on the workpiece, cutting temperatures and thus tool wear, and helps breaking of chips. The objective of this study is to develop a process model for turn-milling operations. In this article, for the first time, uncut chip geometry and tool-work engagement limits are defined for orthogonal, tangential and coaxial turn-milling operations. A novel analytical turn-milling force model is also developed and verified by experiments. Furthermore, matters related to machined part quality in turnmilling such as cusp height, circularity and circumferential surface roughness are defined and analytical expressions are derived.