Beruflich Dokumente
Kultur Dokumente
, Cetin Ozay
University of Frat, Faculty of Technical Education, Department of Machine Education, 23119 Elaz g, Turkey
Received 8 March 2005; received in revised form 20 August 2006; accepted 1 September 2006
Abstract
This paper presents a performance assessment of rotary end milling at the tangential contact. With this shape of the contact, process has been
more stable. At the last decade due to the fact that cutting tools have a quenching problem, Turn-milling has been developing in manufacturing
technology for processing hard steels, where in both the workpiece and the tool are given a rotary movement simultaneously. Thus, cutting edges
have a time for quenching. The objective of present work is to investigate process of tangential turn-milling for machining of workpieces with
in the normally available range of speed and feeds to explore its advantages. The investigations have been laid mainly on surface roughness and
timing process. The experiments have been conducted for tangential turn-milling of mild steel workpiece.
2006 Elsevier B.V. All rights reserved.
Keywords: Turn-milling; Surface roughness
1. Introduction
The turn-milling is a relatively newconcept in manufacturing
technology, where in both, the workpiece and the tool, are given
a rotary movement simultaneously. This process can be broadly
classied into co-axial turn-milling and orthogonal turn-milling
[1]. Co-axial turn-milling in which the axes of the cutter and the
workpiece are parallel to each other, and orthogonal turn-milling
in which the axes of the cutter and the workpiece are perpendic-
ular to each other. Co-axial turn-milling is suitable for internal
as well as external machining of rotationally symmetrical work-
pieces. Orthogonal turn-milling can be used external machining
of rotationally symmetrical workpieces. This new technology
opens up new ranges in the manufacturing processes. Recently,
efforts have been made to substitute the grinding process with
all its problematic strain by methods with geometrically dened
cuttingedges. It has beenobservedthat highspeedturn-millingis
suitable for the precision machining of rotationally symmetrical
workpieces. Hence, when rotationally symmetrical workpieces
are to be manufactured, high speed turn-milling can be alterna-
tive to grinding.
Corresponding author.
E-mail address: vsavas@gmail.com (V. Savas).
With high speed turn-milling, high cutting speeds can be
achieved by utilizing the cutting speeds of tool and the work-
piece. Therefore, the advantages of high speed machining, such
as high surface quality, low thermal stress and low cutting
forces can be achieved. In addition, good cheep removal can be
achieved due to their short length. Hence, turn-milling is a new
prospective technology for the production of precise rotationally
symmetrical workpieces.
Shaw et al. [1] have discussed a novel lathe-type cutting
tool in the form of a disc that may be rotated about its central
axis. Such a rotary tool is found to correspond to an equiva-
lent oblique tool. The rotary tool used by the authors has the
following advantages:
1. It provides a rest period for the cutting edge, thus enabling the
edge to be cooled and the adsorbed lm on the tool surface
to be replenished between cuts.
2. It enables the relative chip velocity to be increased to pro-
vide a lower coefcient of friction without necessitating a
corresponding increase in the metal removal rate.
According to Venuvinod et al. [2], the rotary tool takes the
formof a frustumof a cone. The experiments conducted by them
showed that with a proper selection of rotary speeds, extraordi-
nary effects on the cutting process are observed, e.g., reduction
0924-0136/$ see front matter 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2006.09.040
280 V. Savas, C. Ozay / Journal of Materials Processing Technology 186 (2007) 279283
Fig. 1. Turn-milling process. (a) Orthogonal turn-milling and (bd) tangential turn-milling.
of cutting forces up to 10% and chip thickness ratios lesser than
unity. Chen [3] reported that cutting temperature and cutting
forces are the two dominant parameters that inuence nish
quality and tool life in machining. According to studies con-
ducted by him on the self-propelled rotary tool, it has been
observed that the rotary motion of the cutting edge transfers
heat away from the cutting zone resulting in a reduced cutting
temperature. Cutting forces of the rotary tool are also found to be
smaller thanthose of the xedtool. Armaregoet al. [4] conducted
studies on the driven and the self-propelled rotary tool cutting
operations. It has been shown that the driven oblique rotary tool
cutting process is the most efcient rotary tool process. Konig
et al. [5] worked on the means of reducing production time and
costs for machining hard materials. So far a grinding process
has generally been used to nish materials with hardness val-
ues in excess of 60 HRC, but improved knowledge of process
and the consistent exploitation of modern cutting materials now
enable cutting processes with a geometrically dened edge to
be employed. A variety of machining tasks can be performed
with improved surface quality and high accuracy-to-size dis-
pensing with the need for nish grinding. Higher machining
rates as compared to grinding often result in a reduction in
production times and costs. The pioneer work in the eld of
turn-milling has been carried out in Germany by Schulz and
Spur [6]. The experiments have been conducted for the machin-
ing of roller bearing races using high speed turn-milling. The
study was made for orthogonal as well as co-axial turn-milling
with the emphasis on surface-nish, geometric accuracy and
chip geometry. Schulz and Kneisel [7] have studied turn-milling
with parallel axes as an alternative to precision machining of
hard materials by turning, especially for the machining of work-
pieces where certain limitations for turning exist. It has been
shown that the surface quality of the workpieces is comparable
to the one achieved by grinding and improvement in tool life has
also been reported with optimized cutting conditions. Choud-
hury and Mangrulkar [8] have studied orthogonal turn-milling
and showed as the value of the surface achieved at orthogo-
nal turn-milling is about 10 times lower than that achieved in
the case of turning. Dabade and co-workers [9] have studied
analysis self-propelled round insert milling cutter by taguchi
method.
Conventional studies in this area, usually cutting tool carries
outs the cutting with on orthogonal contact by face edge of tool.
However, in tangential turn-milling process, cutting tool has a
tangential contact with workpiece and cutting process is carried
out through the helix by side edge of cutting tool as Fig. 1.
The aim of the present work is to investigate the innovative
process of tangential turn-milling within the generally available
range of speeds and feeds to explore the advantages of the pro-
cess. The experiments have been conned to the range of cutter
speeds from 300 to 650 rpm and the range of axial feeds from
3.2 to 20 mmmin
1
and workpiece speed speeds from 180 to
450 rpm. The emphasis has been laid mainly on surface-nish of
the workpieces machined by tangential turn-milling. Optimum
value of the surface-nish achieved by tangential turn-milling
has been investigated.
2. Experimental
2.1. Theoretical analysis
The revolution speeds of workpiece and cutting tool in the process both
turning and milling were determined considering cutting tool and workpiece
diameter and workpiece material. During the experiments, both workpiece speed
and tool speed, taking into the consideration of cutting speed, workpiece and
cutter diameter were computed together for an ideal surface roughness as;
V =
DN
1000
(mmin
1
) (1)
where V is the cutting speed of workpiece, D the diameter of workpiece/cutter
and N is the workpiece/cutter speed.
2.2. Experimental set-up
The aim of the experiments was to evaluate the workpiece surface-nish
machined by tangential turn-milling and to compare it with that of turning carried
out under comparable cutting condition.
Experiments onturn-millingwere carriedout ona CNCJHONFORDvertical
milling machine in the accuracy of 0.001 mm. Cylindrical workpiece of SAE
1050 steel of 40 mmdiameter and 100 mmlength were xed between three jaw
universal chuck and rolling center on the machine bed using a special attachment.
Rotation between 180 and 450 rpm were imparted to the job using four-phase
ac electrical motor of 0.75 kW power.
Twenty millimeters diameter end milling cutter of high speed steel material
with four teeth and 15