LAUSR

Abstract Orthogonal turn-milling is a highly efficient and precise cutting technology by combining low-speed rotation of the workpiece, high-speed rotation of the cutter, and moving the cutter along the workpiece. The technology is widely used in aeronautics and astronautics industries to cut various hard-to-machine materials. Orthogonal turn-milling involves more motions than conventional machining operations, for instance turning and milling, and therefore, it is difficult to set the optimum cutting parameters. Cutting force prediction based on cutting layer geometry can be used to optimize cutting parameters in orthogonal turn-milling. However, the cutting layer geometry in orthogonal turn-milling is not well understood. In this work, a method is proposed for assessing different types of cutting layer geometries in orthogonal turn-milling. Each geometry of cutting layer is modelled analytically, which leads to a mathematical model of the corresponding cutting force. The models are validated by cutting experiments. Finally, the cutter wear experiments validate the trends of cutting forces corresponding to the different cutting layer geometries. The present models offer a theoretical guidance for efficient machining strategies in orthogonal turn-milling.