A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools

Patricia Munoz De Escalona, Paul G. Maropoulos

Research output: Contribution to journalArticle

26 Citations (Scopus)

Abstract

Surface quality is important in engineering and a vital aspect of it is surface roughness, since it plays an important role in wear resistance, ductility, tensile, and fatigue strength for machined parts. This paper reports on a research study on the development of a geometrical model for surface roughness prediction when face milling with square inserts. The model is based on a geometrical analysis of the recreation of the tool trail left on the machined surface. The model has been validated with experimental data obtained for high speed milling of aluminium alloy (Al 7075-T7351) when using a wide range of cutting speed, feed per tooth, axial depth of cut and different values of tool nose radius (0.8 mm and 2.5 mm), using the Taguchi method as the Design of Experiments. The experimental roughness was obtained by measuring the surface roughness of the milled surfaces with a non-contact profilometer. The developed model can be used for any combination of material workpiece and tool, when tool flank wear is not considered and is suitable for using any tool diameter with any number of teeth and tool nose radius. The results show that the developed model achieved an excellent performance with almost 98% accuracy in terms of predicting the surface roughness when compared to the experimental data.

LanguageEnglish
Pages216-223
Number of pages8
JournalJournal of Manufacturing Systems
Volume36
Early online date14 Jul 2014
DOIs
Publication statusPublished - Jul 2015

Fingerprint

Surface Roughness
Surface roughness
Face
Prediction
Radius
Experimental Data
Taguchi Method
Tool Wear
Fatigue Strength
Ductility
Model
Surface Quality
Tensile Strength
Design of Experiments
Non-contact
Aluminum Alloy
Taguchi methods
Roughness
High Speed
Design of experiments

Keywords

  • face milling
  • surface roughness
  • Taguchi methods
  • tool run outs

Cite this

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title = "A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools",
abstract = "Surface quality is important in engineering and a vital aspect of it is surface roughness, since it plays an important role in wear resistance, ductility, tensile, and fatigue strength for machined parts. This paper reports on a research study on the development of a geometrical model for surface roughness prediction when face milling with square inserts. The model is based on a geometrical analysis of the recreation of the tool trail left on the machined surface. The model has been validated with experimental data obtained for high speed milling of aluminium alloy (Al 7075-T7351) when using a wide range of cutting speed, feed per tooth, axial depth of cut and different values of tool nose radius (0.8 mm and 2.5 mm), using the Taguchi method as the Design of Experiments. The experimental roughness was obtained by measuring the surface roughness of the milled surfaces with a non-contact profilometer. The developed model can be used for any combination of material workpiece and tool, when tool flank wear is not considered and is suitable for using any tool diameter with any number of teeth and tool nose radius. The results show that the developed model achieved an excellent performance with almost 98{\%} accuracy in terms of predicting the surface roughness when compared to the experimental data.",
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A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools. / Munoz De Escalona, Patricia; Maropoulos, Paul G.

In: Journal of Manufacturing Systems, Vol. 36, 07.2015, p. 216-223.

Research output: Contribution to journalArticle

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AB - Surface quality is important in engineering and a vital aspect of it is surface roughness, since it plays an important role in wear resistance, ductility, tensile, and fatigue strength for machined parts. This paper reports on a research study on the development of a geometrical model for surface roughness prediction when face milling with square inserts. The model is based on a geometrical analysis of the recreation of the tool trail left on the machined surface. The model has been validated with experimental data obtained for high speed milling of aluminium alloy (Al 7075-T7351) when using a wide range of cutting speed, feed per tooth, axial depth of cut and different values of tool nose radius (0.8 mm and 2.5 mm), using the Taguchi method as the Design of Experiments. The experimental roughness was obtained by measuring the surface roughness of the milled surfaces with a non-contact profilometer. The developed model can be used for any combination of material workpiece and tool, when tool flank wear is not considered and is suitable for using any tool diameter with any number of teeth and tool nose radius. The results show that the developed model achieved an excellent performance with almost 98% accuracy in terms of predicting the surface roughness when compared to the experimental data.

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