A general model for uncut chip geometry, process kinematics, and mechanics of orthogonal turn-milling process

Official URL: https://dx.doi.org/10.1016/j.cirpj.2023.02.005

Orthogonal turn-milling as a multi-axis machining operation introduces several advantages compared to conventional turning operations in terms of productivity and accuracy of complex parts. On the other hand, the multi-axis nature of the process adds several complexities in terms of cutter-workpiece engagement (CWE) and process kinematics which eventually affect process mechanics, dynamics, and surface integrity. This study presents generalized and accurate models of CWE, process kinematics, and mechanics to predict the cutting forces in orthogonal turn-milling. To fulfill the gaps in the literature, all the effective parameters such as eccentricity, minor cutting edge geometry, and feed motion are included to address all the possible configurations and conditions in orthogonal turn-milling. The uncut chip geometry is evaluated analytically using process geometry and kinematics. The cutting forces and torque in orthogonal turn-milling are calculated accordingly for standard and serrated end mills. It is shown that this general model is adoptable to the milling tools with complex geometry. The effect of different parameters on cutting forces is examined and verified experimentally.