Journal of Materials Processing Technology 186 (2007) 279283

Analysis of the surface roughness of tangential turn-milling

for machining with end milling cutter
Vedat Savas

, 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

helix rank has been used a cutting tool. Schematic dia-

gram of experimental set-up is shown in Fig. 2. The tangential contact between
V. Savas, C. Ozay / Journal of Materials Processing Technology 186 (2007) 279283 281
Fig. 2. Schematic diagram of the experimental set-up.
cutting tool and workpiece is shown in Fig. 3. The cooling water has not been
used at the experiments. Surface-nish was measured using MITUTOYO 211
Surf test instrument 0.05 mleast count which provided a numerical assessment
of the surface roughness in terms of R
a
values.
2.3. Experimental procedure
Experiments were conducted in two stages to understand the effect of various
machining parameters on the surface roughness. In the rst stage the experiments
were conducted to determine the effect of workpiece speed, at which the cutting
tool speed N
t
was constant level. The experiments were conducted to establish
the effect of following parameters on the surface.
Revolution speed of the work piece, N
w
(rpm): 180, 224, 280, 450.
Depth of the cut, t (mm): 0.1, 0.5, 1.
Axial feed rate f (mmmin
1
): 3.2, 7.9, 12.6, 20.
In the second stage the experiments were conducted to determine the effect
of cutting tool speed, at which the work speed N
w
was constant level. The
experiments were conducted to establish the effect of following parameters on
the surface.
Speed of the cutting tool, N
t
(rpm): 300, 450, 530, 650.
Depth of the cut, t (mm): 0.1, 0.5, 1.
Axial feed rate f (mmmin
1
): 3.2, 7.9, 12.6, 20.
Fig. 3. The process of tangential turn-milling.
3. Results and discussions
3.1. Effect of cutting deep
The inuence of cutting depth can be explained with the help
of a model surface as shown in Fig. 4. In the evident of the model,
a change in deep of cut contributes directly to the change in the
height of surface irregularities. The end milling cutter used for
these experiments can be safely used in the chosen range of deep
of cut. The experiments undertaken have shown that the effect to
the surface roughness of cutting depth is not far too much. Fig. 5
shows the variation of surface roughness, R
a
, between cutting
depth, t, there; the cutter and workpiece speed are at constant
levels.
Fig. 4. Changing of roughness surface and feed rate.
Fig. 5. Effect of depth of cut on surface in tangential turn-milling.
282 V. Savas, C. Ozay / Journal of Materials Processing Technology 186 (2007) 279283
Fig. 6. Effect of axial feed rate on surface in tangential turn-milling.
3.2. Effect of feed rate
The inuence of feed rate on the surface roughness although
deviates from the traditional relationship between feed rate and
surface roughness, it could be due to the relatively closer levels
of feed rate employed during the experiments undertaken. When
the feed rate increased, Surface roughness was increased. Sur-
face roughness occurred during the experiments is due to tool
vibration. Because tool vibration, has been affected due to the
dynamic forces occurred on the tool with increase at feed rate.
Fig. 6 shows the variation of surface roughness, R
a
, between
axial feed rates, f, there; workpiece speed and the cut of depth are
at constant levels. Fig. 7 shows the variation of surface rough-
ness, R
a
, between axial feed rates, f, there; the cutter speed and
the cut of depth are at constant levels.
3.3. Effect of tool and workpiece speed
Fig. 8 shows the variation of surface roughness, R
a
, between
the cutter speeds, N
T
, there; the workpiece speed and the cut of
depth are at constant levels.
Fig. 9 shows the variation of surface roughness, R
a
, between
the workpiece speeds, N
W
, there; the cutter speed and the cut of
depth are at constant levels.
During the experiments, while N
T
is 530 rpm and N
W
is
224 rpm. The optimum results have been obtained. At lower
rotatingspeeds, peripheral speedof tool andworkpiece decrease.
So surface roughness is increased It has been observed that. As
in turning and milling processes the formula (1) used to calculat-
Fig. 7. Effect of axial feed rate on surface in tangential turn-milling.
Fig. 8. Effect of workpiece speed on surface in tangential turn-milling.
Fig. 9. Effect of cutter speed on surface in tangential turn-milling.
ing the rotating speeds of tool and workpiece can be effectively
used in tangential turn-milling process.
Due to the fact that the temperature increases between cutting
tool and workpiece with friction at higher rotating speeds, chip
cut by the tool sticks over cutting edges with the effect of the
high temperature [10]. Therefore, during the experiments, while
N
T
has a value >530 rpm and N
W
has a value >224 rpm, surface
roughness has increased.
4. Conclusion
Based on this work following conclusions can be drawn:
1. The experiments shown that of tangential turn-milling is
different from co-axial turn-milling and orthogonal turn-
milling. Especially to use system of tangential turn-milling
in stead of grinding of rotational symmetrical workpieces,
because the value of R
a
is verycloser togrindingwill decrease
to the production cost in the industry.
2. In the case of tangential turn-milling, an ideal surface quality
for the machined surface, taking into the consideration of
workpiece cutting speed, improves with a value computed of
the cutter and workpiece speed.
3. Averyhighsurface-nishingqualityof machinedsurface can
be achieved by tangential turn-milling for the machining of
rotationallysymmetrical workpieces. Inthe case of tangential
turn-milling, R
a
value of the surface roughness achieved is
lower than that achieved in the case of turning.
4. In the case of tangential turn-milling, very small chips are
produced contrary to the relatively longer chips produced in
V. Savas, C. Ozay / Journal of Materials Processing Technology 186 (2007) 279283 283
the case of turning of SAE 1050 steel. However, the chip
lengths are difference.
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