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A Method for the Determination of Theoretical Roughness in Face Milling Considering the Run-Out of the Inserts

A method is introduced for determining theoretical values of roughness characteristics of surfaces generated by tools having a defined edge geometry. The method is based on the CAD modelling of the theoretical cut surface, and can be used to model practically any complex tool geometry. In application to rotating tools (e.g. face milling), besides the variety of tool designs, the setting accuracy was also taken into consideration during the determination of theoretical values due to the simultaneous cutting of more than one edge. It will be demonstrated that in addition to the determination of 2D roughness parameters, the method is suitable to determine the 3D roughness parameters as the surface topography can be more accurately described with these characteristics. Experimental data is shown to validate of the extended modelling and calculation method.