Int J Adv Manuf Technol (2013) 69:2279–2292
DOI 10.1007/s00170-013-5202-8
ORIGINAL ARTICLE
Research on rotary surface topography
by orthogonal turn-milling
Lida Zhu & Haonan Li & Wansan Wang
Received: 6 February 2013 / Accepted: 15 July 2013 / Published online: 2 August 2013
# Springer-Verlag London 2013
Abstract As a new technology in manufacturing, turn-
milling broadens the application ranges of mechanical pro-
cessing, wherein both cutting tool and workpiece are given a
rotary motion simultaneously. The objective of the present
work is to study workpiece surface topography during orthog-
onal turn-milling process. This study begins with two mathe-
matical models, which describe theoretical surface roughness
and topography of rotationally symmetrical workpiece. The
models are built with the establishment of locus function
according to orthogonal turn-milling principle. Then based
on these models, the influence law of surface topography
affected by various cutting parameters is found by some
simulation methods. The law also matches with orthogonal
turn-milling surface roughness and topography experiments.
By analyzing the experimental results, some parameter selec-
tion criteria during orthogonal turn-milling processing are also
proposed qualitatively and quantitatively. The comparison
between the simulation and experimental results shows that
a better surface quality and tiny oil storage structure can be
obtained if the cutting parameters are chosen in reason. This
conclusion provides a theoretical foundation and reference for
the orthogonal turn-milling mechanism research.
Keywords Orthogonal turn-milling . Surface topography .
Surface roughness . Constructing locus function .
Mathematical modeling
L. Zhu (*) : H. Li : W. Wang
School of Mechanical Engineering and Automation, Northeastern
University, Shenyang 110819, China
e-mail: zld1999@gmail.com
H. Li
e-mail: lhncglx@163.com
1 Introduction
As a newly emerging cutting technology, orthogonal turn-
milling makes use of the advantages of turning and milling,
during which both workpiece and cutting tool are given rotary
motion simultaneously. In the manufacture process, this ma-
chining technology can not only realize a high production rate
and high-quality surface but also be used in external processing
of large-scale rotationally symmetric workpiece [1, 2]. There-
fore, compared with some traditional technologies like turning
or milling, its strengths are considerable, which include low
thermal stress, low cutting force, and so on. In fact, orthogonal
turn-milling has already been an alternative to grinding under
some certain conditions [3–6] and is becoming a hot topic in
machinery manufacturing.
There are some literature researches on this novel technol-
ogy, and the first one is Sorge. In ref. [7], Sorge et al. have
established orthogonal turn-milling fundamentals including
kinematics principle, machined workpiece surface finish and
cutting force, and so on in the 1980s of the twentieth century.
Schulz has studied orthogonal turn-milling in some other
perspectives. In ref. [8, 9], Schulz et al. have stated that the
surface quality of workpiece machined by turn-milling is
comparable to the one achieved by grinding, and by optimized
cutting parameters, tool life would be longer. Besides, he has
also analyzed the affecting factors of surface finish, geometric
accuracy, chip geometry, tool wear, and so forth.
Another interest reference is ref. [10]. In this reference,
Skoric et al. have analyzed the suitability of turn-milling pro-
cess by presenting the theoretical roughness formulas of or-
thogonal turn-milling and turning. And for the sake of a com-
parative estimation of its process, a set of another functions and
methods has also been proposed and defined. She has stated
that turn-milling can machine a workpiece only in one load and
eliminate inevitable error in traditional ones, which are often
produced by moving the workpiece between turning and mill-
ing machines for higher productivity and better surface quality.
2280
Jiang et al. also have studied the forming mechanism of
orthogonal turn-milling manufactured surface and the calcu-
lating method of workpiece theoretical roundness in ref. [11,
12]. In his work, the influence of main cutting parameters on
theoretical roundness has been analyzed and the mathematical
model of surface topography has also been firstly presented,
based on orthogonal turn-milling mechanism. Additionally, he
has proved that different cutting parameters will significantly
influence on surface formation.
Kopac and Pogacink in ref. [13, 14] have described a
complex kinematics process of this technology, the geometry
of the tool and its position. In their study, practical data have
formed a contrast of the roughness between the centric and
eccentric turn-milling under different cutting parameters.
Meanwhile, by their experimental work, it has been shown
that there is a strong influence of vibration on turn-milling
process. Finally, they have emphasized that turn-milling can
lead to a better surface roughness and is much more suitable
for high-speed cutting machining than turning.
Choudhury and Bajpai in ref. [2] and Choudhury and
Mangrulkar in ref. [15] have demonstrated by experiments
that the surface roughness by orthogonal turn-milling raises
with increase of cutter speed and lowers with increase of axial
feed rate. It has also indicated that the roughness of orthogonal
turn-milling is about ten times lower than that of turning.
Moreover, the chips and surface quality of the former one
are smaller and better than those of the latter one. By exper-
iment techniques, some other experiments have been
conducted to study the surface finish, in which mild-steel
workpiece and high-speed steel cutting tools are employed.
Besides, Savas and Ozay in ref. [3, 16] have found a cutting
parameter optimization approach when machining cylindrical
parts. This approach can lead to minimum surface roughness
by using genetic algorithm in the tangential turn-milling pro-
cess, during which the value of surface roughness can be
easily controlled according to cutting parameters.
Also, Liu et al. in ref. [17] have calculated the surface rough-
ness of turn-milling machining miniature parts by experiments.
In his experiments, the relationship between miniaturized turn-
milling parameters and surface roughness has been taken into
consideration and influence degrees of every factor have been
illustrated, respectively. Jin et al. in ref. [18] have clarified the
relation between surface roughness and cutting form in machin-
ing high-strength steel by orthogonal turn-milling. And com-
pared with conventional turning and milling, the low surface
roughness can be easier gained by highly efficient turn-milling.
Although there are a lot of research achievements about
orthogonal turn-milling, most of them mainly focus on surface
roughness instead of surface topography. As a matter of fact,
surface topography has a huge difference when processing by
this new method and traditional cutting, and surface roughness
is just one of important parameters in determining surface
topography and quality. However, the surface texture is an
Int J Adv Manuf Technol (2013) 69:2279–2292
inherently important process response in turn-milling process
and one of most commonly used criteria to determine the
machinability of particular workpiece material. Considering
that it is of great significance in orthogonal turn-milling and
has a directly bearing on affecting machine performance, it is
necessary to deeply research surface topography by both
theory and experiment.
This paper is divided into five main sections; Section 1 will
give four basic motions and five cutting parameters based on
orthogonal turn-milling principle. Section 2 will present two
mathematical models for the calculation of surface roughness
and topography by orthogonal turn-milling discipline, sepa-
rately. Section 3 will discuss six important parameter influ-
ences on orthogonal through approach of simulation by
MATLAB software. The next part, Section 4, is the experi-
ment verification and analysis part, declaring experimental
procedure and measurement as well as surface roughness
experimental results. Finally, in Section 5, some conclusions
from this study are given.
2 Motion relations and cutting parameters in orthogonal
turn-milling
By combining turning and milling processes in one machine,
turn-milling operation is able to produce a variety of surface
topology types on workpiece. Turn-milling involves four ba-
sic motions including rotation of cutter, rotation of workpiece,
axial feed, and radial feed of cutter, as shown in Fig. 1.
Rotation of cutter is the main cutting motion. The cutting
speed is codetermined by rotational speed of cutting tool and
workpiece, wherein rotational speed of cutting tool is the main
factor of cutting speed, especially high turn-milling process.
Motion relations and cutting parameters in orthogonal turn-
milling are shown in Fig. 1.
There are more cutting parameters in orthogonal turn-
milling than those in turning or milling, which contains rota-
tion speed of cutter n1 (r/min), cutting speed vc (mm/min),
axial feed speed vfa (mm/min), axial feed fa (mm/r), feed per
tooth fz (mm/z), depth of cutting ap (mm), etc. There are some
other parameters in a typical orthogonal turn such as work-
piece radius R (mm), eccentricity e (mm), radius of cutter r
(mm), teeth of cutter z, rotational speed of workpiece n2 (r/
min), cutting width w (mm), composed feed velocity vf (mm/
min), angular velocities of cutter, and workpiece w1 and w2
(rad/s), the minimum number of laps when milling cutter can
encircle workpiece N.
(1) Cutting velocity vc
The angular velocity and linear velocity of cutter is a
considerably higher than workpiece in orthogonal turn-
milling, so the rotational motion is considered as main
motion. The cutting velocity is expressed as follows:
Int J Adv Manuf Technol (2013) 69:2279–2292 2281

Fig. 1 Orthogonal turn-milling principle diagram

vc ¼ r ⋅ ω1 ¼ r ⋅ 2π ⋅ n1 ð1Þ From Eq. (7), the feed range per teeth is related with rotational
(2) Feed speed speed of cutter and workpiece, the axial feed range and num-
The tangential feed velocity (workpiece velocity) is ber of teeth and so on.
also expressed by workpiece speed and circumference of
workpiece. (4) Eccentricity
Eccentricity is an important factor in orthogonal turn-


v2 ¼ n2 ⋅ 2π ⋅ R þ ap milling. It is the least distance between axial cords of cutting

 tool and workpiece. Non-eccentricity corresponds to the
¼ ω2 ⋅ R þ a p ð2Þ cutting condition when the least distant is zero. Eccentricity
The feed speed is composed of axial feed speed of cutter and is related with axial feed, which directly affects cutting
tangential feed velocity of cutter relative to workpiece (work- efficiency and quality. In this section, the relation between
piece speed) in Fig. 1. eccentricity and axial feed in turn-milling process is ana-
  qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

ffi lyzed in detail. The maximum axial feed is decided by
v f  ¼ vfa 2 þ ω2 2 ⋅ R þ ap 2 ð3Þ eccentricity, radius, and face edge of cutter and is gained
by adjusting eccentricity in certain cutting tool and work-
piece condition. There are five different eccentricity cases
(3) Feed range shown in Fig. 2.
The tangential feed range: From the relations between eccentricity and axial feed, it

 is shown that the maximum axial feed is gained to reach
f t ¼ 2π ⋅ R þ ap ð4Þ
maximum machining efficiency, when eccentricity is |
e| = r − ls. The machining method is similar to Point
The axial feed range: Grinding, when the axial feed is the least in |e| = r, so
higher machining accuracy is obtained in orthogonal turn-
vfa
fa ¼ ð5Þ milling experiment. It is necessary to match with axial
n2 feed and eccentricity in setting orthogonal turn-milling
parameters.
These relations can be expressed as (5) Theoretical surface roughness
According to its machining principle in Fig. 1, theo-
θz ¼
2πn2
ð6Þ retical roughness RT can be expressed as:
n1 z
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 2ffi
where angle θz is the corresponding rotated angle of work- fz
RT ¼ r − r2 − ð8Þ
piece when cutter turns a tooth. 2
The feed range per teeth is expressed as follows:

qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

 2
  Then, based on (6) (7), and (8), the model of theory surface
v f  n2 f 2a þ 2π⋅ R þ ap
fz ¼ ¼ ð7Þ roughness by orthogonal turn-milling can be expressed as
zn1 zn1 follows:
2282 Int J Adv Manuf Technol (2013) 69:2279–2292
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
8

u 
  9
u < n22 f 2a þ n22 2π ⋅ R − ap 2 = roughness value or workpiece surface shape. The contour of
u 2
RT ¼ r − tr − ð9Þ transversal section is presented to be a polygonal shape.
: 2zn21 ;
Figure 3 is the microscopic photographs of the contour and
its unfolded diagram, in which the contour approximately
tends to have periodic characters.
3 The mathematical model of theoretical surface The contour of cross section is constructed by the locus
topography function as follows:

After the establishment of mathematical model of theoretical       

   
surface roughness, topography can also be defined. Actually, f ðθÞ ¼
1
1 − sin θ  þ cos θ  ð10Þ
surface topography can be expressed by either surface 2  2   2 

Fig. 2 The various eccentricities affect feed rate in axial direction

Int J Adv Manuf Technol (2013) 69:2279–2292 2283

workpiece makes no difference with change in the rota-

ƒ(θ )
tional angle. The model is expressed as follows:
hij ¼ RT
θ       
 i⋅θz   

1
1 − sin þ cos i⋅θz  ð12Þ
2 2   2 
π π π θ
(2) When the ratio is a non-integer, previous machined sur-
face will be cut again. Finally, the formative generatrix of
Fig. 3 Contour of transversal section of work pieces and approximate workpiece surface will be staggered across each other.
curves This model is expressed as,
2  0 1  0 13
 j⋅θz   j⋅θz 
 i⋅θ þ   i⋅θ þ 
16  B z N C  B z N C7
H ij ¼ RT  41 − sin@ A þ cos@ A5
2  2   2 
   
Then, the rotationally symmetrical shape of workpiece is ð13Þ
unfolded to rectangle from θ=0∘ position, wherein the length
of rectangle is the cross section circumference of workpiece
and the width of rectangle is the length of workpiece in X-axis. 4 Surface topography simulation of orthogonal
The positive direction in Y-axis is the same of the angle turn-milling
unfolded direction in workpiece coordinate.
After expansion, the rectangle is divide into kx and ky After mathematical model definition, the surface topography
elements in X and Y direction, respectively, which delegate of orthogonal turn-milling is simulated by MATLAB software
the axial feed fa and rotation angle increment θz. The relative to study the effects of various cutting parameters on the
position height of workpiece surface is expressed with
hij(i=1,2,3,.....k;j=1,2,3,.....k) in kx ×ky gridding, which is
shown in Fig. 4. The function of relative motion parameters Start
f(i,j,θz,fa) is gained by the divided grid method, so mathematic
model of surface topography is expressed as follows
Orthogonal turn-milling principle
hij ¼ RT  f ði; j; θz ; f a Þ ð11Þ

Model of theoretical surface

roughness RT
It also can be summarized that the motion of cutting tool is
made up of two simple ones, rotation and revolution relative to The constructed function
workpiece. So it is obvious that there are also two kinds of for surface topography
number of revolution N, integer ones, and non-integer ones.
To be specific, different mathematic models and simulation N is integer
No
results will be discussed in these two cases.
Yes
(1) When rotational speed ratio between cutting tool and
workpiece is an integer, the closed curves will be gained Mathematics model Mathematics model of
from the revolution, wherein the surface height of of surface topography by surface topography by
orthogonal turn-milling hij orthogonal turn-milling Hij
hij RT f (i, j, z , f a ) Cutting parameters Cutting
Calculation of surface roughness and parameters
ki k j topography

Graphic display of simulation

End

Fig. 4 Machined surface divided by grid Fig. 5 Flow chart of simulation program
2284 Int J Adv Manuf Technol (2013) 69:2279–2292

Table 1 Orthogonal turn-milling

parameters (N=integer) n1 (rpm) n2 (rpm) e (mm) fa (mm/r) ap (mm) z

(a) 2,000 10 3 1 0.5 2, 3, 4

(b) 1,000; 2,000; 3,000 10 3 1 0.5 4
(c) 2,000 5, 10, 20 3 1 0.5 4
(d) 2,000 10 3 0.5, 1, 1.5 0.5 4
(e) 2,000 10 3 1 0.2, 0.5, 0.8 4

surface texture. The detailed flow of modeling and simulation every figure in this part are given in Table 1, including the
is shown in Fig. 5. number of teeth, rotation speed of cutting tool and work-
Following this flow chart, the simulation graphics of to- piece, axial feed rate, cutting depth, and eccentricity.
pography are gained under diverse cutting parameters, such as
(a) The effect of number of teeth on surface topography
cutting depth, number of teeth, rotational speed, and so on. For
As seen in Fig. 6, the number of teeth does not
simulation computation, some initial conditions are given as
affect workpiece surface texture pattern but influence
follows; the workpiece radius R is 40 mm, the length of
surface roughness. And specifically, roughness value
workpiece L is 50 mm, and the cutter radius r is 6 mm.
is decreased with increase of the number of cutting
Considering different rotation speed ratios (integer or non-
tool teeth.
integer) between cutting tool and workpiece result in different
(b) The effect of rotation speed of cutting tool on surface
simulation graphics, we will separately discuss on these two
topography
cases in the following parts.
And when focus on effect of rotational speed of
(1) When rotation speed ratio between cutting tool and cutting tool, it proves to be a similar situation in
workpiece is an integer Fig. 7. Surface texture pattern remains unchanged
To clarify our discussion, all the used parameters in with the change of rotation speed of cutting tool. But
RT/µm

RT/µm

RT/µm

Rotation
Rotation Rotation Length of
Length of Length of of workpiece/rad
of workpiece/rad of workpiece/rad workpiece/mm
workpiece/mm workpiece/mm
Number of teeth =2 Number of teeth=3 Number of teeth=4
Fig. 6 Effect of variable teeth on surface topography
RT/µm
RT/µm

RT/µm

Rotation Rotation Length of Rotation Length of

Length of of workpiece/rad
of workpiece/rad of workpiece/rad workpiece/mm workpiece/mm
workpiece/mm
Rational speed of cutter: 1000 Rational speed of cutter: 2000 Rational speed of cutter:3000
Fig. 7 Effect of rotational speed of cutting tool on surface topography
Int J Adv Manuf Technol (2013) 69:2279–2292 2285

RT/µm

RT/µm

RT/µm
Rotation Rotation
Rotation
of workpiece/rad Length of of workpiece/rad Length of of workpiece/rad Length of
workpiece/mm workpiece/mm workpiece/mm
Rational speed of workpiece: 5 Rational speed of workpiece: 10 Rational speed of workpiece: 20
Fig. 8 Effect of rotational speed of workpiece on surface topography

roughness, on the other hand, is reduced with in-
creasing speed. So, it comes to a conclusion that
rotational speed of cutting tool seriously affects sur-
face topography, especially for high-speed turn-
milling.
(c) The effect of rotation speed of workpiece on surface
topography
Similarly, rotation speed of workpiece also just
influences surface roughness but not texture pattern.
An increment of speed leads to lower surface rough-
ness, which is presented in Fig. 8.
(d) The effect of axial feed rate fa. on surface topography
Another parameter we discussed here is axial feed
rate fa. By Fig. 9, we know that different axial feed
rates are irrelevant to workpiece surface texture pat-
tern but a larger axial feed rate will result in a rougher
machined surface.
(e) The effect of cutting depth ap on surface topography
We also study the effect of cutting depth.
According to Fig. 10, surface texture pattern is not
affected by different cutting depth and the surface
roughness is also not big when the cutting depth is

RT/µm
RT/µm
RT/µm

Rotation
of workpiece/rad Length of Rotation Length of Rotation
of workpiece/rad Length of
workpiece/mm workpiece/mm of workpiece/rad workpiece/mm
Axial feed rate fa=0.5 Axial feed rate fa =1 Axial feed rate fa =1.5
Fig. 9 Effect of axial feed rate on surface topography
RT/µm
RT/µm
RT/µm

Rotation Rotation
Rotation Length of Length of
Length of of workpiece/rad
of workpiece/rad of workpiece/rad workpiece/mm workpiece/mm
workpiece/mm
Cutting depth ap=0.2 Cutting depth ap=0.5 Cutting depth ap=0.8
Fig. 10 Effect of cutting depth on surface topography
2286 Int J Adv Manuf Technol (2013) 69:2279–2292

Table 2 Orthogonal turn-milling

process parameters (N ≠ integer) n1 (rpm) n2 (rpm) e (mm) fa (mm/r) ap (mm) z

(a) 2,000 11 3 1 0.5 2, 3, 4

(b) 1,000; 2,000; 3,000 11 3 1 0.5 4
(c) 2,000 6, 11, 15 3 1 0.5 4
(d) 2,000 11 3 0.5, 1, 1.5 0.5 4
(e) 2,000 11 3 1 0.2, 0.5, 0.8 4

shallow. But when the depth is increased, the chatter
will be generated on the surface of workpiece.
(2) Rotation speed ratio between cutting tool and workpiece
is a non-integer
Some similar simulations are given in this part when the
speed ratio is a non-integer instead of an integer. All the
parameters in every figure in this part are shown in Table 2.
(a) The effect of the number of teeth on surface topography
Figure 11 is the surface topography under the same
RT value as that of last integer condition. In the figure,
texture pattern in the x direction is not a continuous
beeline any more. It presents to be discontinuously
staggered, regularly. It means that texture pattern is
not affected by the teeth number while the surface
roughness is decreased with increase of teeth number.
(b) The effect of rotational speed of cutting tool on
surface topography
But when taking about the parameter of rotation
speed, surface texture pattern is not affected by the
change of it from Fig. 12, but the surface roughness
is decreased with increase in rotational speed of
cutter.
(c) The effect of rotational speed of workpiece on sur-
face topography

RT/µm
RT/µm
RT/µm

Rotation Rotation Rotation

Length of Length of Length of
of workpiece/rad of workpiece/rad of workpiece/rad
workpiece/mm workpiece/mm workpiece/mm
Number of teeth =2 Number of teeth=3 Number of teeth=4
Fig. 11 Effect of variable teeth on surface topography
RT/µm

RT/µm

RT/µm

Rotation Rotation
Length of Rotation Length of of workpiece/rad Length of
of workpiece/rad of workpiece/rad
workpiece/mm workpiece/mm workpiece/mm
Rational speed of cutter: 1000 Rational speed of cutter: 2000 Rational speed of cutter:3000
Fig. 12 Effect of rotational speed of cutting tool on surface topography
Int J Adv Manuf Technol (2013) 69:2279–2292 2287

RT/µm

RT/µm

RT/µm
Rotation Rotation
Rotation
Length of of workpiece/rad Length of of workpiece/rad Length of
of workpiece/rad
workpiece/mm workpiece/mm workpiece/mm
Rational speed of workpiece: 6 Rational speed of workpiece: 11 Rational speed of workpiece: 15
Fig. 13 Effect of rotational speed of workpiece on surface topography

Another similar case is shown in Fig. 13. Surface
texture pattern becomes dense with decrease in rota-
tional speed of workpiece, and surface roughness is
decreased with increase in rotational speed of work-
piece in Fig. 13.
(d) The effect of axial-feed rate fa on surface topography
The relationship between axial feed rate and sur-
face topography is illustrated in Fig. 14. Surface
texture tends to be dense with decrease in axial feed
rate as well as surface roughness is decreased with
decrease in the axial feed rate.
(e) The effect of cutting depth ap on surface topography
The next parameter is cutting depth ap. Surface
RT/µm
texture pattern is not influenced by the change of
cutting depth and there is not a big difference be-
tween different cutting depths (Fig. 15). But if the
cutting depth is increased, chatters will be generated
on surface of workpiece.
5 Orthogonal turn-milling experiments on surface
topography
The orthogonal turning-milling experiment is conducted to
validate the proposed mathematical models. This section begins
with the experimental set-up procedure and the measurement of

RT/µm
RT/µm

Rotation Rotation Rotation

Length of Length of of workpiece/rad Length of
of workpiece/rad workpiece/mm of workpiece/rad
workpiece/mm workpiece/mm
Axial feed rate fa=0.5 Axial feed rate fa =1 Axial feed rate fa =1.5

Fig. 14 Effect of axial feed rate on surface topography

RT/µm

RT/µm
RT/µm

Rotation Length of Rotation Length of Rotation Length of

of workpiece/rad workpiece/mm of workpiece/rad workpiece/mm of workpiece/rad workpiece/mm
Cutting depth ap=0.2 Cutting depth ap=0.5 Cutting depth ap=0.8

Fig. 15 Effect of cutting depth ap on surface topography

2288
Fig. 16 Orthogonal turn-milling process
surface roughness and topography. Then, it goes with some
experimental results and finally ends with some analyses about
these results.
5.1 Experimental set-up procedure and measurement
The experiment of orthogonal turn-milling process is
conducted as shown in Fig. 16, and the results are measured
by CHR 150 Surface Contourgraph as given in Fig. 17. Three
types of workpiece materials including duralumin A212, cop-
per, and 1045# steel are used. The cutters used in the exper-
iment are high-speed steel cutters, with the diameters of
12 mm and the teeth number of two, three, and four, separate-
ly. Besides, some parameter values are also given as follows:
length and diameter of the workpiece are 28 and 80 mm,
respectively.
The procedure of our experiment consists of five steps as
follows:
First, the tool setting of turn-milling is operated to check
cutter position in the workpiece coordinate. To improve the
Fig. 17 Surface contourgraph
Int J Adv Manuf Technol (2013) 69:2279–2292
Fig. 18 Tool setting in turn-milling center
machining precision, the setting point is set followed by
design or technology datum, which can be seen in Fig. 18.
Then, to avoid cutting stress during experiments, ten
grooves are cut on workpiece.
After that, a series of experiments are conducted in accor-
dance with the simulations in Section 3.
After experiments of turn-milling process, machined work-
pieces are cut by DK7732 wire cutting machine, which is
shown in Fig. 19. It is noted that these sections made by
DK7732 need some treatments to protect cutting fluid
corrosion.
Finally, the 3D surface topography and roughness are
measured by 3D surface contourgraph in Fig. 17. To increase
accuracy and reduce random error, five points on the circular
surface of workpiece are detected. Maximum height differ-
ence of surface roughness is measured by using the instru-
ment. During measurement, the circular surface is transformed
into a plane by the command plane and the velocity of
Fig. 19 Cutting off workpiece by wire-electrode cutting
Int J Adv Manuf Technol (2013) 69:2279–2292
a Surface texture (fa=1mm/r)
Fig. 20 3D surface texture of workpiece (N=integer)
contourgraph lens is also controlled under a certain level to
protect collision.
The experimental workpiece surface roughness and texture
pattern are shown in Fig. 20a (when N is an integer). Another
result we can gain from our experiments is the surface height
probability distribution in Fig. 20b. This distribution map
visualizes the proportion and integral distribution law of dif-
ferent heights over the whole surface and is of great signifi-
cance on the lubricity and contact performance of machined
surface. In our case, this distribution is relatively concentrated,
which means much higher wear resistance.
The most common situation in actual processing is the non-
integer situation when N>1, and the complex topography of
this time is shown in Fig. 21. Under the circumstance, cutter
path becomes to a closed curve only after the milling cutter
turns N rounds around the workpiece. Before the curve closes,
Fig. 21 3D surface (N integer)
a fz=0.6mm/z
2289
(b) Probability distribution of heights
every round track of the cutting point does not overlap each
other. This non-coincidence leads to some ripples on work-
piece surface. The peak and tough of these ripples are not in
the same side generatrix. Thus, surface topography of this
time is presented to be some staggered peaks and troughs
and regularly wavy cut marks in both X and Y direction.
For conventional turning process, the theoretical irregular-
ity height of workpiece surface in axial direction is also given
in Fig. 22a. From the figure, we know that there are theoretical
height of irregularities and theoretical waviness of the work-
piece in axial direction and show no regularity. And the reason
for that is the cutter edges are not a completely straight line but
a curved one.
And when it turns to orthogonal turn-milling process, there
is a big difference. The cross section of the workpiece ma-
chined by this method is not an ideal circle but a polygonal
b fz=0.9 mm/z
2290
Fig. 22 Surface of compare
turning with turn-milling
(a) Turning surface
shape. Actually, the distance between the circle and the poly-
gon represents the deviation value of turn-milling, which can
also be seen from Fig. 22b.
5.2 Experimental results of surface topography
After introduction of our experiment procedures and discus-
sion about orthogonal turn-milling disciplines, all the experi-
mental results will be given in this part. We plan our experi-
ments by some experimental techniques and divide all our
work into five sets.
The first set of experiments is about the effect of rotation
speed of cutter and material of workpiece on surface rough-
ness. Some experimental parameters are the following: the
rotation speed of cutter is 10 rpm; the feed rate is 1 mm/r; the
number of teeth is 4; the eccentricity is 6 mm; and the cutting
depth is 0.5 mm.
The results of this set of experiments are illustrated in
Fig. 23. From the figure, we know that surface roughness is
decreased with increase in rotational speed of cutter and
harder material.
Fig. 23 Effect of rotational speed of cutter and material of workpiece on
surface roughness
Int J Adv Manuf Technol (2013) 69:2279–2292
(b) Turn-milling surface
The second set is conducted to study the effect of rotation
speed of workpiece and number of teeth on surface roughness.
There are also some parameters that need to be given here,
which are the following: the rotational speed is 4,000; the feed
rate is 1 mm/r; the eccentricity is 6 mm; and the cutting depth
is 0.2 mm.
The result of experiments is shown in Fig. 24, which
indicates that surface roughness is reduced with increase in
rotational speed of workpiece and the number of teeth.
The next experiment results are given in Fig. 25. In this
experiment, we focus on the effect of axial feed ratio and
eccentricity on surface roughness and some parameters are
the following: the rotational speed is 4,000 rpm; the velocity
of workpiece is 5 rpm; the cutting depth is 0.2 mm; and the
number of teeth is 4.
From this set of experiments, we know that surface rough-
ness is lowered with decrease of axial feed rate and increase of
eccentricity.
Then in the fourth set of experiments, something about the
effect of cutting depth and cutting form on surface roughness
Fig. 24 Effect of rotational speed of workpiece and number of teeth on
surface roughness
Int J Adv Manuf Technol (2013) 69:2279–2292 2291

is researched. Parameters in this experiment: the rotational

speed is 4,000 rpm; the velocity of workpiece is 5 rpm; the
cutting depth is 0.2 mm; and the feed rate is 1 mm/r.
Results show that surface roughness value is smaller in up-
milling than that in down-milling and almost not be affected
by the change of depth as shown in Fig. 26.
The last set of experiments is designed to compare work-
piece surface roughness machined by turn-milling and mill-
ing. The material of workpiece is duralumin A212; the depth
of turn-milling is 0.2 mm; the eccentricity is 4 mm; and the
rotational speed is 10 rpm; and the results are given in Fig. 27.
From the results, it can be concluded that, compared with Fig. 26 Effect of cutting depth and cutting form on surface roughness
milling, orthogonal turn-milling method can gain a better
surface roughness. into smaller feed per tooth, which in turn generates better
surface roughness due to less cutting force and vibration.
Proper axial feeding and rotation speed of workpiece need to
5.3 Analysis of experimental results be properly seleteced in turn-milling. They cannot be too small
because that means low processing efficiency but also cannot
In this section, we will further analyze our experimental be too large and fast because that leads to poor surface quality.
results qualitatively and quantitatively. Some practical conclu- There is a relevant parameter, cutting depth. As long as it is
sions about orthogonal turn-milling method, especially some in a reasonable range, there is not big difference between the
important parameter selection criteria, will also be given here cutting depth and the surface roughness.
to provide references for future research. The last factor is the processing form. It tends to be that up
It is found that the eccentricity has a strong influence on the turn-milling can result in a better surface roughness compared
surface roughness machined by this new method. According with down turn-milling.
to the mechanism of orthogonal turn-milling (both cutter and
workpiece move simultaneously and the resultant movement
of it is a helical movement), it is recommended that the 6 Conclusions
eccentricity should be large enough but not bigger than mill-
ing cutter radius to gain a good surface roughness. This paper studied orthogonal turn-milling method not only in
It is also shown that better surface roughness is achieved theory but also by simulations and experiments. We have
with harder material and higher cutter rotation speed. What is established two mathematical models to predict the roughness
more, the increase of speed means the increase of ratio be- and topography of machined surface. We also have conducted
tween cutter and workpiece, and this increasing ratio will also some simulations by MATLAB software and experiments in
lead to a better unevenness of the machined surface. order to clarify the effect of some parameters on surface
Another parameter needed to note is the number of cutter topography during orthogonal turn-milling processing. At
teeth. With constant feed speed, more teeth number results

Turning
Ra(µm)

Feed (mm/r)
Rational speed 1000(r/min)
Turn-milling
Fig. 25 Effect of axial feed ratio and eccentricity on surface roughness Fig. 27 Surface roughness comparison between turn-milling and turning
2292
last, we have proposed some concrete suggestions about how
to choose cutting parameters to reach high productivity and
surface quality. Some useful references are provided for fur-
ther study about orthogonal turn-milling. Based on this work,
the following conclusions can be drawn:
(1) In orthogonal turn-milling case, the machined surface
improves with increase in rotational speed of the cutter
and deteriorates with increase in axial feed rate. The
surface finish deteriorates with further increase in the
rotational speed of work piece.
(2) In orthogonal turn-milling case, the machined surface
improves with the increase of the number of cutter teeth.
There is not a big difference between different cutting
depths. But if the cutting depth is increased, chatters will
be generated on surface of workpiece.
(3) Orthogonal turn-milling can be an alternative to turning
for the machining of large and heavy workpieces, where
relatively low rotational speeds of the workpieces are
used. In orthogonal turn-milling case, even the cutting
speed is comparably low; a high-surface finish of ma-
chined surface can be achieved.
(4) From the influence law with simulation and experiments,
it can be concluded that a better surface quality and tiny
oil storage structure can be obtained if the cutting param-
eters are chosen in reason.
Acknowledgment This work was supported by (National Natural Sci-
ence Foundation of China) NSFC (51105072) and (51105258), China
Postdoctoral Science Foundation (20110491507), and Doctoral Fund of
Ministry of Education (20110042120019). Thanks to the University of
British Columbia-MAL for helping to complete part of experiment.
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