Available online at www.sciencedirect.com
Procedia CIRP 00 (2014) 000–000
www.elsevier.com/locate/procedia
6th CIRP International Conference on High Performance Cutting, HPC2014
Investigating Eccentricity Effects in Turn-Milling Operations
Emre Uysala ,Umut Karaguzelb, Erhan Budaka,*, Mustafa Bakkalb
a
Manufacturing Research Laboratory, Sabanci University, Istanbul Turkey
b
Faculty of Mechanical Engineering, Istanbul Technical University
* Corresponding author. Tel: +90-216 483 9519 ; fax: +90-216 483 9550. E-mail address: ebudak@sabanciuniv.edu
Abstract
Manufacturing of parts made out of difficult-to-cut materials presents many challenges. Reduced productivity and increased cost due to low
machinability and tool life are main problems in these applications. Turn-milling may offer important advantages in solving these problems.
Turn-milling combines conventional turning and milling processes providing lower cutting temperatures, higher process flexibility and
productivity. Turn–milling processes have additional parameters one of which is the eccentricity between the tool and workpiece axes. The
objective of this study is to develop a process model for eccentricity effects on orthogonal turn-milling operation. Process model includes chip
geometry and cutting force calculations. In addition, effect of eccentricity on tool wear is also investigated in this paper. Although intermitted
characteristics of turn-milling provide benefits such as lower cutting temperature and longer tool life, there are some drawbacks which have to
be taken into consideration. In this direction, analytical definitions related to surface quality such as circularity, surface roughness and cusp
height under the effect of eccentricity are also investigated. Experiments were carried out on a multi tasking CNC machine tool. Analytical
solutions and experimental results are compared to verify the process model.
© 2014 The Authors. Published by Elsevier B.V.
Selection and peer-review under responsibility of the International Scientific Committee of the 6th CIRP International Conference on High
Performance Cutting.
Keywords: Turn-milling;Eccentricity; Tool Wear; Surface Roughness; Circularity
1. Introduction
Market demands for higher quality, reduced leads times
and cost often create need for alternative manufacturing
processes. Within this context, turn-milling, which combines
conventional turning and milling, may offer advantages as a
promising technology. This relatively new process may
provide high productivity and surface quality at the same time
if the conditions are selected properly. In addition, increased
tool life is another potential advantage of turn-milling
especially for difficult-to-cut materials due to intermittent
cutting since cutting temperatures are lower compared to the
ones in conventional turning.
One of the pioneering works on turn-milling was published by
Schulz et. al in 1990 [1]. They categorized turn-milling into
two as co-axial and orthogonal turn-milling. Although coaxial turn-milling is suitable for both external and internal
machining, orthogonal turn-milling can be applied only
external surfaces. They demonstrated on machining of bearing
half liners that high speed turn-milling (HSTM) provides
good chip removal, high surface quality and low cutting
forces. Some of the recent efforts in turn-milling research
have focused on surface quality. Choudhury and Mangrulkar
[2] conducted several orthogonal turn-milling experiments for
two different workpiece materials and compared the results
with conventional turning. They pointed out that Ra value of
surface roughness for orthogonal turn-milling is 10 times
lower than that is obtained by conventional turning.
Choudhury et al. [3] conducted another experimental study on
orthogonal turn-milling where the results were this time
compared with conventional milling demonstrating that the
surface produced by orthogonal turn-milling was better. Savas
et al. [4] investigated surface roughness in tangential turnmilling of rotationally symmetrical workpieces achieving
surface quality comparable to grinding. Kopac and Pogacnik
[5] analyzed eccentricity effects on surface quality in turnmilling. They observed that the roughness value Ra was much
2212-8271 © 2014 The Authors. Published by Elsevier B.V.
Selection and peer-review under responsibility of the International Scientific Committee of the 6th CIRP International Conference on High Performance Cutting.
Uysal et al. / Procedia CIRP 00 (2014) 000–000
better in eccentric turn-milling. In addition, Yuan and Zheng
[6] focused on developing a geometric model for turn-milling
operation in order to predict the surface roughness in an
effective way. They investigated the effects of turn-milling
process parameters on surface roughness. Huang et al. [7]
studied optimization of turn- milling parameters in terms of
tool wear. They tried to develop a cutting acreage model to
observe the cutting parameters effect on tool wear. There
have been also studied about turn-milling kinematics.
Karaguzel et. al [8] carried out extensive amount of testing
with zero eccentricity demonstrating significant increases up
to 20 times in tool life using turn milling instead of
conventional turning for the machining of difficult to cut
materials such as waspaloy and nickel alloys.
Neagu et al. [9] pointed out that turn-milling can reach 20
times greater productivity than rough turning operation of
straight shafts. Analytical cutting force models were also
developed for turn-milling Filho [10] conducted experiments
on a five axis machining center while measuring cutting
forces, and compared them with an analytical model. Jiang
[11] illustrated the effects of turn-milling process parameters
on surface textures obtained by tangential condition. In
another study Jiang by Zhu et al. [12] investigated the process
parameters effects on surface roughness by simulations.
The main objective of this paper is to develop a
comprehensive geometric model for eccentric orthogonal
turn-milling operations which covers chip thickness,
machined surface quality and tool wear. Tool wear tests were
carried on multi-tasking machine tool in order to investigate
the eccentricity effects on process. For prediction of part
quality, circumferential surface roughness and cusp height are
formulated. Furthermore, material removal rate (MRR) is
specified and optimized by taking into account tool wear and
machined part quality.
Nomenclature
vf
feed speed
ap
axial depth of cut
ae
feed per workpiece revolution
fz
feed per tooth
z
number of teeth
nw
rotational speed of workpiece
nt
rotational speed of tool
rn
rotational speed ratio of tool over workpiece
Rw
radius of workpiece
Rt
radius of tool
Dt
diameter of tool
e
eccentricity
Φst
immersion start angle
Φex
immersion exit angle
Ln
minor cutting edge length of the tool insert
ch
cusp height
β
feed mark angle
θ
angle between facets
MRR material removal rate
aecrit critical feed per workpiece revolution
circrough roughness in circumferential direction
2
2. Experimental Setup
Fig. 1a shows Mori Seiki NTX 2000 Multi-Tasking Machine
on which the turn-milling experiments were conducted. In
addition, the primary axes and milling spindle are shown in
Fig.1b. Tool spindle can rotate around only Y axes but can
move linearly along the X, Y and Z axes. As a result of this
configuration turning, milling and turn-milling operations can
be performed on this machine.
a
b
Fig. 1. a)Mori Seiki NTX 2000 multi tasking machine b) possible axes
on the machine tool.
AISI 1050 Steel was chosen as workpiece material both for
force and tool wear experiments. In tool wear experiments 32
mm Seco Micro-Turbo 217.69-03 milling tool with three
cutting teeth was used with MP2500 grade inserts. Cutting
conditions used in orthogonal turn-milling experiments are as
follows: 300 m/min cutting speed, 0.15 mm/tooth feed, 1 mm
depth of cut and 8 mm feed per workpiece revolution.
Eccentricity is another important parameter in orthogonal
turn-milling and it can be defined as the Y offset according to
the workpiece rotation angle (Fig. 2).
Because of the tool rotational and workpiece axial
simultaneous movements, there are two different feeds in
turn-milling process. The effect of the eccentricity parameter
was investigated for four different values (0mm, 10mm,
21mm, 25mm) by using a 50mm diameter Seco milling tool
with four teeth.
a
b
c
Fig. 2. a) 3D schematic representation b) concentric (eccentricity=0)
case c) eccentric case of orthogonal turn-milling.
The effect of eccentricity on both tool wear and surface
roughness were investigated for different cutting conditions.
In order to measure tool wear, Nanofocus µsurf 3D
profilometer is used at regular time intervals.
a
b
Fig. 3. a) Nanofocus µsurf b) Cutting insert and Nanofocus image in
orthogonal turn-milling.
Uysal et al. / Procedia CIRP 00 (2014) 000–000
In all measurements after a certain cutting period, the inserts
were chosen randomly and placed on measuring device to
determine the flank wear (Fig. 3).
a
b
3
Fig. 6 represents the chip formation in Case 2. When
eccentricity is increased, there is no more uncut chip beyond
the tool axis and governing equations become as follows;
If x1<x<x2
(3)
h  tan( )*( x  x1 )
If x2<x<x3
h  Rw2  ( x  2)2  ( Rw  a p )
(4)
Fig. 4. a) Mitutoyo portable surface roughness tester b) surface roughness
test setup.
Chip formation is crucial from the point of cutting
mechanics, heat generation and stability. Eccentricity in
orthogonal cutting changes engagement boundaries, and in
turn, the chip thickness as well. Analysis of chip formation
including eccentricity effects show that chip formation can be
separated into three cases. For all cases h represents the chip
height in Z direction with respect to x. In addition, x
represents the incremental length on the X axis.
a
Beyond a certain value of eccentricity, chip is formed only by
the side of the cutting tool.
(5)
h  Rw2  ( x  2)2  ( Rw  a p )
Considering all three cases, one can obtain a general
expression for the uncut chip geometry including eccentricity
effect. Fig. 8 shows uncut chip area with respect to immersion
angle for different eccentricity values under the cutting
conditions of Rt=4 mm, ap=1mm, θ=1° and Rw=45 mm.
Although Φst depends on the Rt and ae , Φex is always 180°.
0.8
0.7
2
3. Eccentricity Effect on Chip Formation
Fig. 7. Cross section of uncut chip in Case 3.
Uncut Chip Area(mm )
Mitutoyo portable surface roughness tester is used to measure
the surface roughness of workpiece. In order to obtain
reliable measurements, specimens were clamped on a chuck
and the measurements were taken at different locations on the
workpiece. The measurement devices and the set-up are
illustrated in Fig. 4.
b
0.6
0.5
e=0mm
e=0.5mm
e=1 mm
e=1.5mm
e=3.5mm
e=4 mm
0.4
0.3
0.2
0.1
20
40
60
Immersion Angle
80
Fig. 8. Uncut chip area for different eccentricity values.
4. Eccentricity Effect on Turn-Milling
Fig. 5a shows the cross section of uncut chip in Case 1 which
represents the configuration where there is a piece of uncut
chip beyond the tool axis. Moreover, Fig. 5b represents the
adjacent tool locations in cutting process which creates chip.
For case 1, the chip thickness can be evaluated by the
following equations.
4.1. Material Removal Rate
Material removal rate (MRR) determines the productivity
in a machining process. MRR is proportional to the axial and
radial depth of cuts similar to the conventional milling
process. Actually ae in this equation has the same role of
radial depth of cut in conventional milling, and should be used
as such in the MRR calculation.
MRR  v f * a p * ae
(6)
If 0<x<x2
v f  z * nt * f z
Fig. 5. Cross section of uncut chip in Case 1.
h  tan( )* x  (( Rw  a p )* tan( / 2)  e)* tan( )
(1)
If x2<x<x3
h  Rw2  ( x  2)2  ( Rw  a p )
(7)
MRR in turn-milling can be limited due to surface finish
quality. Fig. 9 illustrates form errors in turn-milling.
(2)
a
b
c
Fig. 6. Cross section of uncut chip in Case 2.
Fig. 9. Form errors in orthogonal turn-milling.
aecrit
2
Cusp Height(mm)
0.4
0.4
0.3
0.2
0.2
0
40
Cusp Height(mm)
1.8
0.6
2.5
1.6
2
1.4
1.5
1.2
1
1
0.8
0.5
0.6
0
0
0
400
300
30
50
100
150
100
10
0
0
100
rn
0
10
20
30
40
50
60
70
2
30
1.5
20
1
Eccentricity
Cusp
10
0
0
10
20
30
0.5
40
50
60
70
80
90
100
0
110
Percentage ae/Dt
e=21 [Simulation]
e=23 [Simulation]
e=21 [Experimental]
0.8
Cusp Height(mm)
0.7
e=23 [Experimental]
*
0.6
0.5
0.4
0.3
0.2
for e=21mm case
upto 25mm/rev
no cusp
for e=23mm case
upto 20mm/rev
no cusp
0.1
0
5
10
15
20
25
30
35
40
ae [mm/rev]
Fig. 12. Verification of cusp height model.
Fig. 12 points out both simulation is obtained from the
analytical model and experimental results for the same cutting
parameters. The cutting parameters are chosen same as it is
defined in Fig. 11. It can be clearly understood from the
figure that up to a certain value of ae there is no cusp which
increases with e. In addition, ae can be increased up to 25
mm/rev for the optimum eccentricity value.
0.4
50
200
20
ae(mm/rev)
0.1
0
80
0
b
0.5
0
40
0.9
(10)
0.6
0.8
2
2.5
The effects of both ae and eccentricity on the cusp height by
using equation 9 is shown in Fig. 11a. Cutting parameters
used in simulation can be summarized as follows; ap=5 mm,
Rw=50 mm, z=4, Rt=25 mm, Ln=4 mm, rn=200 and fz=0.2
mm/rev-teeth. For the same ae value, an increase in the
amount of the eccentricity results in higher cusp height. In
addition, the figure also illustrates the MRR for the same
parameters by using equation 6. Although increasing MRR
decreases the manufacturing time, it also increases the cusp
height. Hence, first ae must be selected to obtain an acceptable
cusp height value. Moreover, Fig. 11b shows the
corresponding ae and cusp height values for a selected
eccentricity. For the same eccentricity value when ae/Dt is
increased from 60% to 80%, the cusp height is raised by
86%while MRR is increased by 25%.
2
ae can be increased up to the critical value given by equation
10 without producing any cusp. As a result, MRR can be
increased
without
sacrificing
surface
quality
in
circumferential direction.
a
0.5
3
50
Fig. 11. Orthogonal turn-mill parameters effect on cusp height.
 e
2
ch  ( Rw  a p )   e  ( Rw  a p ) x tan 
     ( Rt )       ( Rw  a p )
  
 2   
 z x rn    


 
 180   

 2 x ( Rt )2   e  ( Rw  a p ) x tan 
 z xr   
 
n  

 
4
60
Percentage ae/Dt
2

1
b
6
Cusp Height
MRR for e=21mm
MRR for e=22mm
MRR for e=23mm
MRR for e=24mm
MRR for e=25mm
Material Removal Rate [cm3/sec]
1.5
Eccentricity (% of Dt)
decreasing tool radius.
a
Cusp Height[mm]
Both tool and workpiece simultaneous rotations result in
polygon shape cross section. This form error named as
circularity through in this paper. The polygon shaped part
cross-section containing facets are a result of simultaneous
tool and workpiece rotational movements. The time between
subsequent cutting tool engagements with workpiece is the
main parameter which directly affects the number of facets on
the machined surface. In orthogonal turn-milling, as the
cutting edge engages with the work while it rotates, the work
surface also moves due to the workpiece rotation. It results in
a certain time period where there is no contact between the
cutting edge and the finished surface until the next tooth
reaches to the finished surface. The time period between these
two contact instants of the subsequent teeth with the finished
surface determines the facet width, and thus the number of
facets on the periphery of the cylindrical workpiece. Equation
8 illustrates the geometrical implementation of θ angle, which
represents the angle between subsequent facet middle points
and related to number of facets.
360 
(8)
θ
z x rn
As it can be understood from the equation above, number of
facets is independent from eccentricity parameter. Cusp which
is another circumferential form error in orthogonal turnmilling and shown in Fig. 9, is the height of remaining
material during tool motion and directly associated with the
tool, workpiece diameter and step over. Step over can be
defined as the size of the cutter’s diameter that is engaged in a
cut. The optimum eccentricity is e=Rt-Ln. In this case because
of maximum contact length between tool and workpiece is
obtained, highest ae can be defined without observing cusp.
The geometrical representation of cusp height is;
2
(9)
2
 
 180    
a 
4
Cusp Height[mm]
Uysal et al. / Procedia CIRP 00 (2014) 000–000
Rw
200
0.2
0
Rt
Fig. 10. Cusp height simulations.
The effect of ae, rn, Rw and Rt on cusp by using equation 9 is
shown in Fig. 10. The cutting parameters in the simulation are
as follows; ap=5 mm, e=21 mm z=4, nt=2000 rpm, nw=10
rpm, Rt=25 mm, Rw=50 mm, fz=0.12 mm/rev-teeth. Although
ae has a negative effect, the speed ratio rn, has a positive effect
on cusp height as shown in Fig. 10a. Furthermore, increasing
rn improves MRR. From Fig. 10b it can be seen that the tool
radius has bigger influence on the cusp height compared to
the workpiece radius where the cusp height increases with
4.2. Circumferential Surface Roughness
Simultaneous rotational movement of both tool and
workpiece causes spiral shape feed marks along the
workpiece axis.
a
b
Fig. 13. Example tool path for orthogonal turn-mill operation.
Uysal et al. / Procedia CIRP 00 (2014) 000–000
As illustrated in Fig. 13, higher ae results in feed marks which
have higher helix angles on the surface. The angle between
this trochoidal path and the normal line is given by equation
11 which is derived from the triangle between sequential tool
path revolutions.


ae
β  arctan 
 4( R  a ) 
w
p 

(11)
The circumferential surface roughness is indirectly affected
from angle β. During the measurement of circularity or
circumferential roughness, a probe or a needle contacts the
workpiece at desired number of points along the full circle.
These desired and well-distributed points are located at the
same distance from the base plane. β angle affects the slope of
the feed marks on workpiece. Therefore, the distribution of
the cusps along the full circle is changed.
a
b
5
As it is represented in Fig. 15a, increasing in rn and
decreasing ae reduce surface roughness in the circumferential
direction. In addition, effects of rn and ae on the
circumferential surface roughness are similar to those on the
cusp height. On the other hand, there is a linear relationship
between tool and workpiece and circumferential surface
roughness as shown in Fig. 15b Furthermore, conversely to
the Fig. 15a, radius of workpiece effect on circular form error
is bigger than radius of the tool.
4.3. Axial Surface Roughness
Surface roughness in a turn-milling operation is affected
by a relatively high number of factors as this process is a
combination of milling and turning. In conventional
processes, surface roughness generally depends on the feed
and tool radius. The wiper inserts, which have modified radial
corner to clean the surface, remove more material with their
back side. In other words, this kind of inserts increase the tool
workpiece engagement length. On the other hand, increasing
compressive forces is the main drawback of using wiper insert
in machining operation.
a
b
Fig. 14. Geometrical definition of circumferential surface roughness.
2

 180   
( Rt ) 2  e    Rw  a p  x tan 
 

 z x rn   

 ( Rw  a p )
tan 
  arctan
( Rw  a p )
(12)
α determines the location of point B where the cusp height is
taken into consideration.
  90    ch
 90     ( Rw  a p )
circrough  
x
 ( Rw  a p )   
x
  
 
 180   cos
  180  2
(13)
a
0.14
b
-4
x 10
13
0.2
0.12
0.15
0.1
0.1
0.08
0.05
0.06
0.04
0
40
0
30
100
20
200
10
12
-3
x 10
11
1.5
10
1
9
8
0.5
7
6
0
200
20
150
40
100
400
60
50
300
0
ae(mm/rev)
0.02
Circumferential Roughness(mm)
Circumferential Roughness(mm)
In order to formulate the circumferential surface roughness
the workpiece in cylindrical direction divided into two parts
which are indicated with three points as shown in Fig. 14.
Between point A and B, the surface roughness can be defined
with the circularity form error. Point B represents the
transition point in terms of circumferential surface roughness
from circularity to cusp height. After point B, cusp height
effect is included in the surface roughness calculation. In
addition, from the point B to the C, the cusp height is
increased continuously up to maximum value that’s why
circular roughness equation contains weighted average.
Equation 13 is derived based on this approach At the half of
the peripheral path cusp height takes its maximum value. If
the ae is chosen less than or equal to aecrit, only circularity will
be observed as circumferential form error. In other words,
aecrit is the limit value for producing surfaces without any cusp
height.
rn
Rw
80
0
100
Rt
Fig. 15. Circumferential surface roughness simulations.
5
4
3
Fig. 16. Effects of orthogonal turn-milling parameters on surface roughness.
Fig. 16 illustrates cutting parameters effect on surface
roughness based on experiments in axial direction of the
workpiece. Cutting parameters used in the experiments can be
summarized as follows; ap=0.5 mm, z=4, nt=3000 rpm, nw=20
rpm and ae= 3 mm/rev. For standard insert, when eccentricity
is increased, surface roughness decreases dramatically. On the
other hand, for wiper inserts surface roughness increases with
increasing eccentricity until an optimum value because
increasing eccentricity decreases the tool workpiece
engagement length which is the positive effect of wiper insert.
When eccentricity becomes equal to the cutter radius only
side edges of the cutting tool take parts in cutting process.
Moreover, there is not a worthwhile relationship between rn
and alongside surface roughness. As a result, rn can be
increased as much as possible.
As far as it is observed from the experiments, the surface
produced by the wiper insert is generally better than with the
ones generated by standard inserts for a given feed rate. In
other words, in order to obtain same acceptable surface
roughness limit, feed rate for wiper insert case can be defined
higher than standard insert case. By this way, productivity can
be increased. Using the same cutting conditions, for some
cases up to 10 times better surface roughness was achieved
with wiper insert in orthogonal turn-milling. If the feed rate is
bigger than the wiper insert’s minor cutting edge length, the
number of wiper insert on the face mill tool must be
increased. As illustrated in Fig. 17 increasing eccentricity
eliminates wiper insert’s positive effect on the surface
roughness since the engagement length between the tool and
the workpiece is reduced by increasing eccentricity. Although
Uysal et al. / Procedia CIRP 00 (2014) 000–000
wiper insert’s positive effect on the surface roughness is
decreased with increased eccentricity, surface roughness is
still better compared to standard insert except when the
eccentricity equals to optimum value (e=21mm). For this
case, for relatively small feed [mm/rev] values, the wiper
insert has no worthwhile effect on surface roughness.
Fig. 17. Variation of surface roughness improvement with eccentricity.
4.4. Tool Wear
Stephenson et al. [13] point out that for the same cutting
conditions intermittent cutting produces less cutting
temperature than in continuous cutting operations. Because it
contains cutting and non-cutting periods in each cycle which
provides time to cool down. By this way, thermal based tool
wear on cutter was reduced. Thus, one of the most significant
advantages of turn-milling is increased tool life [8]. In order
to understand the eccentricity effects on tool life, experiments
were conducted on AISI 1050 steel and Seco Duratomic 50
mm diameter milling tool with four teeth was used.
Fig. 18. Eccentricity effect on tool wear in AISI 1050 Steel.
Fig. 18 illustrates tool wear results with respect to cutting
length, which is calculated for individual tooth, for different
eccentricity values. When the eccentricity is equal to optimum
value (e=21mm) the engagement length between workpiece
and tool reaches its maximum level which contributes more
uniform distribution of the pressure on cutting tool. As a
consequence of this, the tool life reaches its maximum for
e=21mm. In this experiment cutting tool, which have 25mm
radius and 4mm minor cutting edge length, is used. The
difference between these values determines the optimum
eccentricity value which provides the maximum engagement
length between tool and workpiece. Selection of eccentricity
as almost nearly the cutting tool radius (e=21mm) will result
in the highest tool life. However, there is a limit for this
improvement. When eccentricity becomes equal to the cutting
tool radius, the engagement length between the tool and
workpiece decreases dramatically. At this position, only the
side edges of the cutting tool participate in the cutting zone.
As a result, excessive cutting loads are exerted on a small part
of cutting tool which causes decreased tool life.
6
5. Conclusion
The present paper describes effects of eccentricity in
orthogonal turn-milling starting with the chip formation. From
geometrical analysis, relationships between tool, workpiece
and eccentricity are developed. A surface roughness model in
circumferential direction is also introduced, and simulated for
different conditions to demonstrate the effects of process
parameters on surface quality. It is shown that by using this
model, process parameters can be determined to increase the
MRR without sacrificing surface quality. Extensive cutting
tests are conducted to investigate the eccentricity effects on
both tool life and axial surface roughness, and the results are
discussed.
Acknowledgements
The support from Tubitak (Project 110M522), Mori Seiki and
Pratt and Whitney Canada for this research is appreciated by
the authors.
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