Surface Roughness Generation and Material Removal Rate in Ball End Milling Operations

Abstract

Surface roughness plays an important role in the performance of a finished part. Surface roughness generated in machining operations is influenced by an enormous set of factors such as cutting parameters, cutting tool characteristics, workpiece properties, or cutting phenomena. Cutting geometric characteristics, when ball end mill is used, clearly affect surface crests generated. In this paper, we study the influence of the geometric characteristics of ball end mill cut on the theoretical surface roughness obtained. The crests height on the surface (h) and roughness average parameter (Ra) are calculated as function of cutting tool radius (R) and radial depth of cut (Ae). Surface angularity is also considered. This work also analyzes cutting parameters implication on material removal rate (MRR) of ball end milling operations. The equations and especially the figures presented in this paper can be easily applied in workshops to improve quality and productivity of ball end milling operations. Finally, experimentation carried out permits to observe and quantify the deviations of the theoretical approach.