Available online at ScienceDirect. 6th CIRP International Conference on High Performance Cutting, HPC2014

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1 Aville online t ScienceDirect Procedi CIRP 4 ( 4 ) th CIRP Conference on High Performnce Cutting, HPC4 Investigting Eccentricity Effects in Turn-Milling Opertions Emre Uysl,Umut Krguzel, Erhn Budk,*, Mustf Bkkl Mnufcturing Reserch Lortory, Snci University, Istnul Turkey Fculty of Mechnicl Engineering, Istnul Technicl University * Corresponding uthor. Tel: ; fx: E-mil ddress: eudk@snciuniv.edu Astrct Mnufcturing of prts mde out of difficult-to-cut mterils presents mny chllenges. Reduced productivity nd incresed cost due to low mchinility nd tool life re min prolems in these pplictions. Turn-milling my offer importnt dvntges in solving these prolems. Turn-milling comines conventionl turning nd milling processes providing lower cutting tempertures, higher process flexiility nd productivity. Turn milling processes hve dditionl prmeters one of which is the eccentricity etween the tool nd workpiece xes. The ojective of this study is to develop process model for eccentricity effects on orthogonl turn-milling opertion. Process model includes chip geometry nd cutting force clcultions. In ddition, effect of eccentricity on tool wer is lso investigted in this pper. Although intermitted chrcteristics of turn-milling provide enefits such s lower cutting temperture nd longer tool life, there re some drwcks which hve to e tken into considertion. In this direction, nlyticl definitions relted to surfce qulity such s circulrity, surfce roughness nd cusp height under the effect of eccentricity re lso investigted. Experiments were crried out on multi tsking CNC mchine tool. Anlyticl solutions nd experimentl results re compred to verify the process model. 4 4 The Pulished Authors. y Pulished Elsevier B.V. Open ccess under CC BY-NC-ND license. y Elsevier B.V. Selection Selection nd nd peer-review peer-review under under responsiility responsiility of the of the Scientific Scientific Committee Committee of the of 6th the CIRP 6th CIRP Conference Conference on High on Performnce High Performnce Cutting. Cutting Keywords: Turn-milling;Eccentricity; Tool Wer; Surfce Roughness; Circulrity. Introduction Mrket demnds for higher qulity, reduced leds times nd cost often crete need for lterntive mnufcturing processes. Within this context, turn-milling, which comines conventionl turning nd milling, my offer dvntges s promising technology. This reltively new process my provide high productivity nd surfce qulity t the sme time if the conditions re selected properly. In ddition, incresed tool life is nother potentil dvntge of turn-milling especilly for difficult-to-cut mterils due to intermittent cutting since cutting tempertures re lower compred to the ones in conventionl turning. One of the pioneering works on turn-milling ws pulished y Schulz et. l in 99 []. They ctegorized turn-milling into two s co-xil nd orthogonl turn-milling. Although coxil turn-milling is suitle for oth externl nd internl mchining, orthogonl turn-milling cn e pplied only externl surfces. They demonstrted on mchining of ering hlf liners tht high speed turn-milling (HSTM) provides good chip removl, high surfce qulity nd low cutting forces. Some of the recent efforts in turn-milling reserch hve focused on surfce qulity. Choudhury nd Mngrulkr [] conducted severl orthogonl turn-milling experiments for two different workpiece mterils nd compred the results with conventionl turning. They pointed out tht R vlue of surfce roughness for orthogonl turn-milling is times lower thn tht is otined y conventionl turning. Choudhury et l. [3] conducted nother experimentl study on orthogonl turn-milling where the results were this time compred with conventionl milling demonstrting tht the surfce produced y orthogonl turn-milling ws etter. Svs et l. [4] investigted surfce roughness in tngentil turnmilling of rottionlly symmetricl workpieces chieving surfce qulity comprle to grinding. Kopc nd Pogcnik [5] nlyzed eccentricity effects on surfce qulity in turnmilling. They oserved tht the roughness vlue R ws much Pulished y Elsevier B.V. Open ccess under CC BY-NC-ND license. Selection nd peer-review under responsiility of the Scientific Committee of the 6th CIRP Conference on High Performnce Cutting doi:.6/j.procir.4.3.4

2 Emre Uysl et l. / Procedi CIRP 4 ( 4 ) etter in eccentric turn-milling. In ddition, Yun nd Zheng [6] focused on developing geometric model for turn-milling opertion in order to predict the surfce roughness in n effective wy. They investigted the effects of turn-milling process prmeters on surfce roughness. Hung et l. [7] studied optimiztion of turn- milling prmeters in terms of tool wer. They tried to develop cutting crege model to oserve the cutting prmeters effect on tool wer. There hve een lso studied out turn-milling kinemtics. Krguzel et. l [8] crried out extensive mount of testing with zero eccentricity demonstrting significnt increses up to times in tool life using turn milling insted of conventionl turning for the mchining of difficult to cut mterils such s wsploy nd nickel lloys. Negu et l. [9] pointed out tht turn-milling cn rech times greter productivity thn rough turning opertion of stright shfts. Anlyticl cutting force models were lso developed for turn-milling Filho [] conducted experiments on five xis mchining center while mesuring cutting forces, nd compred them with n nlyticl model. In nother study, Jing y Zhu et l. [] investigted the process prmeters effects on surfce roughness y simultions. The min ojective of this pper is to develop comprehensive geometric model for eccentric orthogonl turn-milling opertions which covers chip thickness, mchined surfce qulity nd tool wer. Tool wer tests were crried on multi-tsking mchine tool in order to investigte the eccentricity effects on process. For prediction of prt qulity, circumferentil surfce roughness nd cusp height re formulted. Furthermore, mteril removl rte (MRR) is specified nd optimized y tking into ccount tool wer nd mchined prt qulity. Nomenclture v f feed speed p xil depth of cut e feed per workpiece revolution f z feed per tooth z numer of teeth n w rottionl speed of workpiece n t rottionl speed of tool r n rottionl speed rtio of tool over workpiece R w rdius of workpiece R t rdius of tool D t dimeter of tool e eccentricity Φ st immersion strt ngle Φ ex immersion exit ngle L n minor cutting edge length of the tool insert ch cusp height β feed mrk ngle θ ngle etween fcets MRR mteril removl rte ecrit criticl feed per workpiece revolution circ rough roughness in circumferentil direction. Experimentl Setup Fig. shows Mori Seiki NTX Multi-Tsking Mchine on which the turn-milling experiments were conducted. In ddition, the primry xes nd milling spindle re shown in Fig.. Tool spindle cn rotte round only Y xes ut cn move linerly long the X, Y nd Z xes. As result of this configurtion turning, milling nd turn-milling opertions cn e performed on this mchine. Fig.. ()Mori Seiki NTX multi tsking mchine; () possile xes on the mchine tool. AISI 5 Steel ws chosen s workpiece mteril oth for force nd tool wer experiments. In tool wer experiments 3 mm Seco Micro-Turo milling tool with three cutting teeth ws used with MP5 grde inserts. Cutting conditions used in orthogonl turn-milling experiments re s follows: 3 m/min cutting speed, mm/tooth feed, mm depth of cut nd 8 mm feed per workpiece revolution. Eccentricity is nother importnt prmeter in orthogonl turn-milling nd it cn e defined s the Y offset ccording to the workpiece rottion ngle (Fig. ). Becuse of the tool rottionl nd workpiece xil simultneous movements, there re two different feeds in turn-milling process. The effect of the eccentricity prmeter ws investigted for four different vlues (mm, mm, mm, 5mm) y using 5mm dimeter Seco milling tool with four teeth. Fig..() 3D schemtic representtion; () concentric (eccentricity=) cse; (c) eccentric cse of orthogonl turn-milling. The effect of eccentricity on oth tool wer nd surfce roughness were investigted for different cutting conditions. In order to mesure tool wer, Nnofocus μsurf 3D profilometer is used t regulr time intervls. c Fig. 3. () Nnofocus μsurf; () Nnofocus imge of cutting insert

3 78 Emre Uysl et l. / Procedi CIRP 4 ( 4 ) 76 8 In ll mesurements fter certin cutting period, the inserts were chosen rndomly nd plced on mesuring device to determine the flnk wer (Fig. 3). Fig. 6 represents the chip formtion in Cse. When eccentricity is incresed, there is no more uncut chip eyond the tool xis nd governing equtions ecome s follows; If x <x< x htn( )*( x x ) (3) If x <x<x 3 h R ( x) ( R ) (4) w w p Fig. 4. () Mitutoyo portle surfce roughness tester; () surfce roughness test setup. Mitutoyo portle surfce roughness tester is used to mesure the surfce roughness of workpiece. In order to otin relile mesurements, specimens were clmped on chuck nd the mesurements were tken t different loctions on the workpiece. The mesurement devices nd the set-up re illustrted in Fig Eccentricity Effect on Chip Formtion Chip formtion is crucil from the point of cutting mechnics, het genertion nd stility. Eccentricity in orthogonl cutting chnges enggement oundries, nd in turn, the chip thickness s well. Anlysis of chip formtion including eccentricity effects show tht chip formtion cn e seprted into three cses. For ll cses h represents the chip height in Z direction with respect to x. In ddition, x represents the incrementl length on the X xis. Fig. 5. Cross section of uncut chip in Cse. Fig. 5 shows the cross section of uncut chip in Cse which represents the configurtion where there is piece of uncut chip eyond the tool xis. Moreover, Fig. 5 represents the djcent tool loctions in cutting process which cretes chip. For cse, the chip thickness cn e evluted y the following equtions. If <x<x htn( )* x(( R )*tn( /) e)*tn( ) () If x <x<x 3 w w p w p h R ( x) ( R ) () Fig. 6. Cross section of uncut chip in Cse. Beyond certin vlue of eccentricity, chip is formed only y the side of the cutting tool. h R ( x) ( R ) (5) w w p Considering ll three cses, one cn otin generl expression for the uncut chip geometry including eccentricity effect. Fig. 8 shows uncut chip re with respect to immersion ngle for different eccentricity vlues under the cutting conditions of R t =4 mm, p =mm, θ= nd R w =45 mm. Although Φ st depends on the R t nd e, Φ ex is lwys 8. Uncut Chip Are(mm ) 4. Eccentricity Effect on Turn-Milling 4.. Mteril Removl Rte Mteril removl rte (MRR) determines the productivity in mchining process. MRR is proportionl to the xil nd rdil depth of cuts similr to the conventionl milling process. Actully e in this eqution hs the sme role of rdil depth of cut in conventionl milling, nd should e used s such in the MRR clcultion. MRR v * * (6) f p e v z* n * f (7) f t z Fig. 7. Cross section of uncut chip in Cse e=mm e=mm e= mm e=.5mm e=3.5mm e=4 mm Immersion Angle Fig. 8. Uncut chip re for different eccentricity vlues. MRR in turn-milling cn e limited due to surfce finish qulity. Both tool nd workpiece simultneous rottions result in polygon shpe cross section which nmed s circulrity through this pper. The polygon shpe contining fcets re result of simultneous tool nd workpiece rottionl

4 Emre Uysl et l. / Procedi CIRP 4 ( 4 ) movements. Fig. 9 illustrtes form errors in turn-milling. on cusp height s shown in Fig.. Furthermore, incresing r n improves MRR. From Fig. it cn e seen tht the tool rdius hs igger influence on the cusp height compred to the workpiece rdius where the cusp height increses with decresing tool rdius. c Fig. 9. Form errors in orthogonl turn-milling. The time etween susequent cutting tool enggements with workpiece is the min prmeter which directly ffects the numer of fcets on the mchined surfce. In orthogonl turn-milling, s the cutting edge engges with the work while it rottes, the work surfce lso moves due to the workpiece rottion. It results in certin time period where there is no contct etween the cutting edge nd the finished surfce until the next tooth reches to the finished surfce. The time period etween these two contct instnts of the susequent teeth with the finished surfce determines the fcet width, nd thus the numer of fcets on the periphery of the cylindricl workpiece. Eqution 8 illustrtes the geometricl implementtion of θ ngle, which represents the ngle etween susequent fcet middle points nd relted to numer of fcets. 36 θ (8) zxr n As it cn e understood from the eqution ove, numer of fcets is independent from eccentricity prmeter. Cusp which is nother circumferentil form error in orthogonl turn-milling nd shown in Fig. 9, is the height of remining mteril during tool motion nd directly ssocited with the tool, workpiece dimeter nd step over. Step over cn e defined s the size of the cutter s dimeter tht is engged in cut. The optimum eccentricity is e=r t -L n. In this cse ecuse of mximum contct length etween tool nd workpiece is otined, highest e cn e defined without oserving cusp. The geometricl representtion of cusp height is; 8 e ( w p) ( w p) tn ( t) ( w p) zxrn ch R e R x R R e cn e incresed up to the criticl vlue without producing ny cusp. As result, MRR cn e incresed without scrificing surfce qulity in circumferentil direction. Cusp Height(mm) e(mm/rev) r n 3 4 Cusp Height(mm) Fig.. Cusp height simultions. The effect of e, r n, R w nd R t on cusp y using eqution 9 is shown in Fig.. The cutting prmeters in the simultion re s follows; p =5 mm, e= mm z=4, n t = rpm, n w = rpm, R t =5 mm, R w =5 mm, f z = mm/rev-teeth. Although e hs negtive effect, the speed rtio r n, hs positive effect R w 5 R t 5 (9) Cusp Height[mm].5 Cusp Height MRR for e=mm MRR for e=mm MRR for e=3mm MRR for e=4mm MRR for e=5mm Percentge e/d t 6 4 Mteril Removl Rte [cm 3 /sec] Eccentricity (% of D t ) Eccentricity Cusp Percentge e/d t Fig.. Orthogonl turn-mill prmeters effect on cusp height. The effects of oth e nd eccentricity on the cusp height y using eqution 9 is shown in Fig.. Cutting prmeters used in simultion cn e summrized s follows; p =5 mm, R w =5 mm, z=4, R t =5 mm, L n =4 mm, r n = nd f z = mm/rev-teeth. For the sme e vlue, n increse in the mount of the eccentricity results in higher cusp height. In ddition, the figure lso illustrtes the MRR for the sme prmeters y using eqution 6. Although incresing MRR decreses the mnufcturing time, it lso increses the cusp height. Hence, first e must e selected to otin n cceptle cusp height vlue. Moreover, Fig. shows the corresponding e nd cusp height vlues for selected eccentricity. For the sme eccentricity vlue when e /D t is incresed from 6% to 8%, the cusp height is rised y 86%while MRR is incresed y 5%. Cusp Height(mm) * e= [Simultion] e=3 [Simultion] e= [Experimentl] e=3 [Experimentl] for e=3mm cse upto mm/rev no cusp e [mm/rev] Fig.. Verifiction of cusp height model. Fig. points out oth simultion is otined from the nlyticl model nd experimentl results for the sme cutting prmeters. The cutting prmeters re chosen sme s it is defined in Fig.. It cn e clerly understood from the figure tht up to certin vlue of e there is no cusp which increses with e. In ddition, e cn e incresed up to 5 mm/rev for the optimum eccentricity vlue. 4.. Circumferentil Surfce Roughness Simultneous rottions of tool nd workpiece cuse spirl shpe feed mrks long the workpiece xis. As shown in Fig. 3, higher e results in feed mrks which hve higher helix ngles on the surfce. The ngle etween this trochoidl pth nd the norml line is given y eqution which is derived from the tringle etween sequentil tool pth revolutions for e=mm cse upto 5mm/rev no cusp Cusp Height[mm]

5 8 Emre Uysl et l. / Procedi CIRP 4 ( 4 ) 76 8 Fig. 3. Exmple tool pth for orthogonl turn-mill opertion. e β rctn 4( Rw p ) () The circumferentil surfce roughness is indirectly ffected from ngle β. During the mesurement of circulrity or circumferentil roughness, proe or needle contcts the workpiece t desired numer of points long the full circle. These desired nd well-distriuted points re locted t the sme distnce from the se plne. β ngle ffects the slope of the feed mrks on workpiece. Therefore, the distriution of the cusps long the full circle is chnged. Fig. 4. Geometricl definition of circumferentil surfce roughness. roughness s shown in Fig. 5. Furthermore, conversely to the Fig. 5, rdius of workpiece effect on circulr form error is igger thn rdius of the tool. Circumferentil Roughness(mm)..5 4 e(mm/rev) Fig. 5. Circumferentil surfce roughness simultions Axil Surfce Roughness 4 3 r n Circumferentil Roughness(mm) x -3.5 Surfce roughness in turn-milling opertion is ffected y reltively high numer of fctors s this process is comintion of milling nd turning. In conventionl processes, surfce roughness generlly depends on the feed nd tool rdius. The wiper inserts, which hve modified rdil corner to clen the surfce, remove more mteril with their ck side. In other words, this kind of inserts increse the tool workpiece enggement length. On the other hnd, incresing compressive forces is the min drwck of using wiper insert in mchining opertion. 5 Rw 5 8 Rt 6 4 rctn 8 ( Rt) e Rw pxtn zxr n ( Rw p) tn ( R ) w p () α determines the loction of point B where the cusp height is tken into considertion. 9 ( Rw p) 9 ch circrough x ( Rw p) x 8 cos 8 () In order to formulte the circumferentil surfce roughness the workpiece in cylindricl direction divided into two prts which re indicted with three points s shown in Fig. 4. Between point A nd B, the surfce roughness cn e defined with the circulrity form error. Point B represents the trnsition point in terms of circumferentil surfce roughness from circulrity to cusp height. After point B, cusp height effect is included in the surfce roughness clcultion. In ddition, from the point B to the C, the cusp height is incresed continuously up to mximum vlue tht s why circulr roughness eqution contins weighted verge. Eqution is derived sed on this pproch At the hlf of the peripherl pth cusp height tkes its mximum vlue. If the e is chosen less thn or equl to ecrit, only circulrity will e oserved s circumferentil form error. In other words, ecrit is the limit vlue for producing surfces without ny cusp height. As it is represented in Fig. 5, incresing in r n nd decresing e reduce surfce roughness in the circumferentil direction. In ddition, effects of r n nd e on the circumferentil surfce roughness re similr to those on the cusp height. On the other hnd, there is liner reltionship etween tool nd workpiece nd circumferentil surfce Fig. 6. Effects of orthogonl turn-milling prmeters on surfce roughness. Fig. 6 illustrtes cutting prmeters effect on surfce roughness sed on experiments in xil direction of the workpiece. Cutting prmeters used in the experiments cn e summrized s follows; p = mm, z=4, n t =3 rpm, n w = rpm nd e = 3 mm/rev. For stndrd insert, when eccentricity is incresed, surfce roughness decreses drmticlly. On the other hnd, for wiper inserts surfce roughness increses with incresing eccentricity until n optimum vlue ecuse incresing eccentricity decreses the tool workpiece enggement length which is the positive effect of wiper insert. When eccentricity ecomes equl to the cutter rdius only side edges of the cutting tool tke prts in cutting process. Moreover, there is not worthwhile reltionship etween r n nd longside surfce roughness. As result, r n cn e incresed s much s possile. As fr s it is oserved from the experiments, the surfce produced y the wiper insert is generlly etter thn with the ones generted y stndrd inserts for given feed rte. In other words, in order to otin sme cceptle surfce roughness limit, feed rte for wiper insert cse cn e defined higher thn stndrd insert cse. By this wy, productivity cn e incresed. Using the sme cutting conditions, for some cses up to times etter surfce roughness ws chieved with wiper insert in orthogonl turn-milling. If the feed rte is igger thn the wiper insert s minor cutting edge length, the

6 Emre Uysl et l. / Procedi CIRP 4 ( 4 ) numer of wiper insert on the fce mill tool must e incresed. As illustrted in Fig. 7 incresing eccentricity elimintes wiper insert s positive effect on the surfce roughness since the enggement length etween the tool nd the workpiece is reduced y incresing eccentricity. Although wiper insert s positive effect on the surfce roughness is decresed with incresed eccentricity, surfce roughness is still etter compred to stndrd insert except when the eccentricity equls to optimum vlue (e=mm). For this cse, for reltively smll feed [mm/rev] vlues, the wiper insert hs no worthwhile effect on surfce roughness. Fig. 7. Vrition of surfce roughness improvement with eccentricity Tool Wer Stephenson et l. [] point out tht for the sme cutting conditions intermittent cutting produces less cutting temperture thn in continuous cutting opertions. Becuse it contins cutting nd non-cutting periods in ech cycle which provides time to cool down. By this wy, therml sed tool wer on cutter ws reduced. Thus, one of the most significnt dvntges of turn-milling is incresed tool life [8]. In order to understnd the eccentricity effects on tool life, experiments were conducted on AISI 5 steel nd Seco Durtomic 5 mm dimeter milling tool with four teeth ws used. Fig. 8. Eccentricity effect on tool wer in AISI 5 Steel. Fig. 8 illustrtes tool wer results with respect to cutting length, which is clculted for individul tooth, for different eccentricity vlues. When the eccentricity is equl to optimum vlue (e=mm) the enggement length etween workpiece nd tool reches its mximum level which contriutes more uniform distriution of the pressure on cutting tool. As consequence of this, the tool life reches its mximum for e=mm. In this experiment cutting tool, which hve 5mm rdius nd 4mm minor cutting edge length, is used. The difference etween these vlues determines the optimum eccentricity vlue which provides the mximum enggement length etween tool nd workpiece. Selection of eccentricity s lmost nerly the cutting tool rdius (e=mm) will result in the highest tool life. However, there is limit for this improvement. When eccentricity ecomes equl to the cutting tool rdius, the enggement length etween the tool nd workpiece decreses drmticlly. At this position, only the side edges of the cutting tool prticipte in the cutting zone. As result, excessive cutting lods re exerted on smll prt of cutting tool which cuses decresed tool life. 5. Conclusion The present pper descries effects of eccentricity in orthogonl turn-milling strting with the chip formtion. From geometricl nlysis, reltionships etween tool, workpiece nd eccentricity re developed. A surfce roughness model in circumferentil direction is lso introduced, nd simulted for different conditions to demonstrte the effects of process prmeters on surfce qulity. It is shown tht y using this model, process prmeters cn e determined to increse the MRR without scrificing surfce qulity. Extensive cutting tests re conducted to investigte the eccentricity effects on oth tool life nd xil surfce roughness, nd the results re discussed. Acknowledgements The support from Tuitk (Project M5), Mori Seiki nd Prtt nd Whitney Cnd for this reserch is pprecited y the uthors. References [] Schulz G., Spur G. High Speed Turn-Milling New Precision Mnufcturing Technology for the Mchining of Rottionlly Symmetricl Workpieces. CIRP Ann Mnuf Technol 99;39():7 9. [] Choudhury SK., Mngrulkr KS. Investigtion of Orthogonl Turnmilling for the Mchining of Rottionlly Symmetricl Workpieces. J Mter Process Technol ;99: 8. [3] Choudhury SK., Bjpi JB. Investigtion in Orthogonl Turn-milling Towrds Better Surfce Finish. J Mter Process Technol 4;7: [4] Svs V., Ozy C. Anlysis of the Surfce Roughness of Tngentil Turnmilling for Mchining with End Milling Cutter. J Mter Process Technol 7;86: [5] Kopc J., Pogcnik M. Theory nd Prctice of Achieving Qulity Surfce in Turn Milling. Int. J. Mch. Tools Mnufct. Vol. 995;37:No. 5. pp [6] Yun S., Zheng W. The Surfce Roughness Modeling on Turn-milling Process nd Anlysis of Influencing Fctors. Applied Mechnics nd Mterils Vols.; 7-9. p [7] Hung C., Ci Y. Turn-milling Prmeters Optimiztion Bsed on Cutter Wer. Advnced Mterils Reserch Vols.; p [8] Krguzel U., Olgun U., Uysl E., Budk E., Bkkl M. High Performnce Turning of High Temperture Alloys on Multi-tsking Mchine Tools. New Production Technologies in Aerospce Industry Lecture Notes in Production Engineering; 4. p. -9. [9] Negu C., Gheorghe M., Dumitrescu A. Fundmentls on Fce Milling Processing of Stright Shfts. J Mter Process Technol 5;66: [] Filho J. Prediction of Cutting Forces in Mill Turning Through Process Simultion Using Five-xis Mchining Center. The Journl of Advnced Mnufcturing Technology, Vol.; 58. p.7. [] Zhu L., Li H., Wng W. Reserch on Rotry Surfce Topogrphy y Orthogonl Turn-milling. Int J Adv Mnuf Technol; 3. [] Stephenson A., Ali A. Tool Tempertures in Interrupted Metl Cutting. Journl of Engineering for Industry y ASME 99;4:7-36.

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