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Analytical modeling on 3D chip formation of rotary surface in orthogonal turn-milling

Zhu L., Li H., Liu C.

Archives of Civil and Mechanical Engineering

2016

Vol. 16, no. 4

590--604

Orthogonal turn-milling is a relatively new process technology, the coupling turning and milling processes together and enjoying the advantages of both. However, to the best knowledge of the authors, few studies on the chips of the orthogonal turn-milling have been reported, although the understanding of the chips is important when studying turn-milling mechanism, machining heat and tool wear. In this paper, the analytical models of 3D chips (under both centric and eccentric situations) are proposed based on the orthogonal turn-milling principle and the mathematical expressions of chip thickness and height are obtained considering both side and end cutting edges. Based on the models, numerical analysis is performed to understand the relationships between chip dimensions and cutting parameters. To verify the proposed models and numerical results, the validation experiments are conducted. The comparison shows the consistency between theoretical and experimental results in terms of chip geometries and volumes under different cutting speeds and feed rates. Some findings are presented based on this study, which might provide a theoretical foundation and reference for the orthogonal turn-milling mechanism research.

Investigation of the length of segment in orthogonal turn-milling (OTM)

Hassan A.I., Kosmol J.

Prace Naukowe Katedry Budowy Maszyn / Politechnika Śląska

2000

nr 1

231-242

A relatively new process for machining of rotationally symmetrical workpieces could be achieved, if the rotation of the workpiece is combined with the motion of a rotating milling cutter, i.e. orthogonal turn-milling (OTM) process. In this paper, a theoretical study of the process kinematics was carried out. The effect of the working conditions; e.g. feed, speed ratio, depth of cut and relative position between the cutter and the workpiece axes, on the length of segment on the workpiece cross sectional contour was investigated in detail. The experimental results revealed that the speed ratio, plays an important role in affecting the length of segment while the depth of cut has no significant influence.

Stosunkowo nowy proces skrawania przedmiotów obrotowo-symetrycznych można uzyskać łącząc obrót przedmiotu z ruchem obrotowym freza. Nazywany jest procesem ortogonalnym toczenia - frezowania. W artykule przedstawiono teoretyczne aspekty procesu z punktu widzenia kinematyki. Szczegółowo przedstawiono wpływ posuwu, stosunku prędkości, głębokości skrawania, położenia ostrza względem osi przedmiotu na długości segmentu skrawanego. Badania eksperymentalne pokazują, że stosunek prędkości posiada bardzo duży wpływ na długość segmentu, podczas gdy głębokość skrawania niezbyt duży.