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Roughness profile in high speed face milling operation

Abstract In face milling operation, the machined surface quality depends on several factors, e.g. feed, cutting speed, machine vibrations, worked material, chip thickness, tool geometry and errors in the positioning of cutting inserts. In this work, radial and axial errors have been considered. A numerical model for the prediction of the surface profile has been developed. It permits the surface profile and the roughness parameters to be determined in relation to cutting conditions, tool geometry, tool–workpiece materials and insert position errors. To analyse experimentally the evolution of surface roughness in connection with cutting parameters, the experimental design system method has been used. The frequency of the vibration behaviour of the cutting process obtained by undulation profile has been incorporated in the model.