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

Patricia Muñoz-Escalona*, Paul G. Maropoulos

*Corresponding author for this work

    Research output: Contribution to journalArticle

    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 aluminum 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. © 2014 The Society of Manufacturing Engineers.

    Original languageEnglish
    Article number309
    Pages (from-to)216-223
    Number of pages8
    JournalJournal of Manufacturing Systems
    Volume36
    Early online date14 Jul 2014
    DOIs
    Publication statusPublished - 2015

    Fingerprint

    Surface roughness
    Taguchi methods
    Design of experiments
    Wear resistance
    Surface properties
    Ductility
    Aluminum alloys
    Tensile strength
    Wear of materials
    Engineers

    Bibliographical note

    *

    Keywords

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

    Cite this

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    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 aluminum 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. {\circledC} 2014 The Society of Manufacturing Engineers.",
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    A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools. / Muñoz-Escalona, Patricia; Maropoulos, Paul G.

    In: Journal of Manufacturing Systems, Vol. 36, 309, 2015, p. 216-223.

    Research output: Contribution to journalArticle

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