Abstract
The removal of as much allowance as possible is an important aspect in improving efficiency of part manufacturing. The goal is to achieve the highest possible surface rate during this process and thus the highest possible feed is recommended for a given allowance. However, the roughness of machined surfaces increases with increasing feed depending on the shape, number and location of the edges. Since roughness values in face milling can change even when applying inserts with identical edge geometry – both in planes parallel with the feed direction and in planes at an angle to it – it is particularly important to be able to plan the roughness characteristics of surfaces. A method for modelling surface topography is introduced that takes into account the standard factors, the variety of tool designs, and different tool edge geometries as well as the accuracy of the tool setting. Modelled 2D-3D parameters and real roughness data are compared, and CAD modelling of the generated topography with increased feed and the validation of experimental data are presented.
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