Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Experimental and numerical investigation of the turn-milling process on 1.7225 steel

Document Type : Original Article

Authors
Reza Saebi Rad 1
Saeed Amini 1
Reza Mahdipour 2
1 Faculty of Mechanical Engineering, University of Kashan, Isfahan, Iran
2 Faculty of Mechanical Engineering, Amirkabir University of Technology, Tehran, Iran
10.22034/ijme.2026.537602.2114
Abstract
Turn-milling is a hybrid machining process that combines turning and milling operations, in which both the tool and the workpiece rotate simultaneously. This configuration provides high flexibility for machining curved and complex surfaces. The present study investigates, through both experimental tests and numerical simulations, the influence of key independent machining parameters—namely, workpiece rotational speed, tool rotational speed, and tool feed rate—on cutting responses such as cutting forces and specific cutting energy. The results indicate that increasing the tool feed rate leads to higher cutting force components and lower specific cutting energy. Experimental findings show that tripling the tool feed rate increases the machining force by approximately 2.3 times and reduces specific cutting energy by about 27%. Numerical simulations performed in ABAQUS predict a 2.7-fold increase in machining force and a 4% reduction in specific cutting energy for a similar threefold increase in the tool feed rate.
Keywords
Turn-Milling
Specific Cutting Energy
Cutting Force
ABAQUS Software
[1] Choudhury S, Bajpai J. Investigation in orthogonal turn-milling towards better surface finish. Journal of Materials Processing Technology. 2005 Jan 15;170(3):487–493. doi: 10.1016/j.jmatprotec.2004.12.010
[2] Berenji KR, Karagüzel U, Özlü E, Budak E. Effects of turn-milling conditions on chip formation and surface finish. CIRP Annals. 2019 Jan 1;68(1):113-6. doi: 10.1016/j.cirp.2019.04.067
[3] Schulz H, Spur G. High speed turn-milling—a new precision manufacturing technology for the machining of rotationally symmetrical workpieces. CIRP annals. 1990 Jan 1;39(1):107-9. doi: 10.1016/S0007-8506(07)61013-0
[4] Pogacnik M, Kopac J. Dynamic stabilization of the turn-milling process by parameter optimization. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2000 Feb 1;214(2):127-35. doi: 10.1243/0954405001517504
[5] Lei S, Liu W. High-speed machining of titanium alloys using the driven rotary tool. International journal of machine tools and manufacture. 2002 May 1;42(6):653-61. doi: 10.1016/S0890-6955(02)00012-3
[6] Savas V, Ozay C. Analysis of the surface roughness of tangential turn-milling for machining with end milling cutter. Journal of Materials Processing Technology. 2007 Feb 19;186(1–3):27–38. doi: 10.1016/j.jmatprotec. 2006.09.040
[7] Karagüzel U, Lazoglu I, Altintas Y, Budak E. Analytical modeling of turn-milling process geometry, kinematics and mechanics. International Journal of Machine Tools and Manufacture. 2015 Mar;91:24–33. doi: 10.1016/j.ijmachtools.2014.11.014
[8] Karagüzel U, Özlü E, Budak E. Effects of tool axis offset in turn-milling process. Journal of Materials Processing Technology. 2016 Feb;231:239–247. doi: 10.1016/j.jmatprotec.2015.12.020
[9] Amini S, Baraheni M, Khaki M. Empirical study on ultrasonic assisted turn-milling. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. 2021 Jun;235(3):699–708. doi: 10.1177/09544089211008714
[10] Amini SJ, Saebi Rad R. Experimental investigation of the effect of changes in the machining parameters of the turn-milling process. Modares Mechanical Engineering. 2023;23(10):43-9. [In Persian]
[11] Sun J, Li P, Zhang S, Chen Y, Lu H, Chen G, Shao D. Simulation and experimental study of ultrasonic vibration-assisted milling of GH4169 high-temperature alloy. Alexandria Engineering Journal. 2023 Jul;73:403–413. doi: 10.1016/j.aej.2023.04.065
[12] Feng X, Dong Z, Li B, Peng H. Finite element simulation and experimental analysis of axial ultrasonic vibration-assisted micro-milling of 316L stainless steel. The International Journal of Advanced Manufacturing Technology. 2024 Aug;133(9):4365-83. doi: 10.1007/s00170-024-13807-1
[13] Huahong M, Wenchao X, Lan W, Ziyuan Z, Zhibiao T, Zhibiao L. Experimental study and modeling of cutting force in high-speed milling of Ti-6Al-4V titanium alloy. Journal of Mechanics. 2025;41:55-63. doi: 10.1093/jom/ufaf006
[14] Liu X, Shan C, Xiong Y, Zhou C. Modeling and simulation for orthogonal cutting force in ultrasonic vibration–assisted machining in situ TiB2/Al MMCs. The International Journal of Advanced Manufacturing Technology. 2025 Mar;137(3):1667-82. doi: 10.1007/s00170-025-15260-0
[15] Fischer U, Gomeringer R, Heinzler M, Kilgus R, Näher F, Oesterle S, Paetzold H, Stephan A. Manual de tecnologia metal mecânica. Editora Blucher; 2011.
[16] Maftah A. Finite element simulation of orthogonal metal cutting using an ALE approach [master's thesis]. Fredericton (NB): University of New Brunswick; 2008.
[17] Kiliçaslan C. Modelling and simulation of metal cutting by finite element method. Master’s degree thesis. Ýzmir Institute of Technology, Turkey. 2009 Dec.
[18] Arrazola PJ, Özel T, Umbrello D, Davies M, Jawahir IS. Recent advances in modelling of metal machining processes. Cirp Annals. 2013 Jan 1;62(2):695-718. doi: 10.1016/j.cirp.2013.05.006
[19] Jafarian F, Amirabadi H, Sadri J. Integration of finite element simulation and intelligent methods for evaluation of thermo-mechanical loads during hard turning process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2013 Feb;227(2):235-48. doi: 10.1177/0954405412466995
[20] DeMange JJ, Prakash V, Pereira JM. Effects of material microstructure on blunt projectile penetration of a nickel-based super alloy. International Journal of Impact Engineering. 2009 Aug 1;36(8):1027-43. doi: 10.1016/j.ijimpeng.2009.01.007
[21] Wang K. Calibration of the Johnson–Cook failure parameters as the chip separation criterion in the modelling of the orthogonal metal cutting process [doctoral dissertation]. Dayton (OH): Wright State University; 2016.