An experimental study on surface errors in orthogonal turn-milling process

Turn-milling as a multi-axis machining operation has recently become a significant operation in the industry due to its advantages in terms of productivity, precision and tool life. However, due to simultaneous rotation of tool and workpiece, some dimensional drawbacks can be generated on the machined surface. Solving these errors need more profound analysis compared to conventional machining operations. I this regard, process geometry and cutting mechanics are studied in this work to understand the sources and reasons of surface errors. A predictive chip model is developed and analyzed with regard to tool offset. Moreover, the effect of different tool geometries on surface profile is studied experimentally.