Abstract
In the present paper, the variation of surface roughness of machined parts during symmetrical face milling is investigated. During this experimental work, the effect of using a milling insert with a round geometry under various feed rate values on the topography of milled parts is examined. For that purpose, both 2D and 3D surface roughness measurements were performed in three planes parallel to the feed direction, with one of the planes being on the symmetrical plane and the other two being at the same distance from it but in opposite sides. The analysis of the experimental results indicated that although surface roughness increases gradually with increase of feed rate, a considerable increase of surface roughness occurs for feed rate values over 0.4 mm/tooth. Moreover, the overall higher surface roughness values were found to be on the symmetrical plane, which was also more affected by the increase of feed rate than the other two planes.
Highlights
Surface quality of mechanical components is considered very crucial, as it is one of the main indicators of surface integrity and it was shown to affect produced parts’ life directly [1]
After the face milling experiments were carried out, surface roughness measurements were performed on the machined samples, each repeated three times and the results were processed by the aforementioned software in order to determine the values of surface roughness parameters
In addition to the average values of 2D and 3D surface roughness parameters, the recorded 2D and 3D surface roughness profiles will be afterwards presented in Figures 3 and 4 for fz = 0.1, 0.3 and 0.8 mm/tooth, in order to show more directly the effect of different feed rate values on the surface topography during face milling
Summary
Surface quality of mechanical components is considered very crucial, as it is one of the main indicators of surface integrity and it was shown to affect produced parts’ life directly [1]. Improved machining performance was observed at intermediate and high speeds [3,4]; on the contrary, lower values of cutting speed were related to built-up edge creation and chip fracture, leading to deterioration of surface quality [2,3]. The increase of feed rate, axial and radial depth of cut lead to surface quality deterioration [2,3,4] and the feed rate is considered as the parameter that mostly affects surface roughness [5,6]
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