Modeling the surface roughness in face-end milling process by using general insert at stable cutting conditions

Predicting the quality of the machined components is the grandiose signification in industrial manufacturing. Calculation of the surface roughness is one of the most important elements to predict the quality of machined parts. In this paper, the surface roughness was modeled in the face-end mill process by using general rhombu insert. In the proposed mathematical model, with the stable milling condition, the surface roughness is formulated by a function of feed rate, and insert geometry such as nose radius and nose angle. An experimental method is proposed based on the stable milling condition to estimate the surface roughness. The developed surface roughness calculation model has been successfully verified by both simulation and experiment with very promising results. The average difference between predicted and experimental results is 7.59%. The proposed model can be applied to predict the surface roughness in face-end mill processes by using general insert at stable cutting condition.