Surface topography model with considering corner radius and diameter of ball-nose end miller.

Surface topography, as one of the significant roles in surface integrity, has a great impact on the performances and service life of the machined parts. This research focuses on the surface topography model for the ball-nose end miller in machining of AISI P20 steel. First, the model is developed to predict the surface topography and surface roughness in ball-nose end milling process. Secondly, the accuracy of the developed surface topography model was verified by a series of milling experiments. Thirdly, the effects of corner radius and diameter of ball-nose end miller on surface roughness is analyzed, it is observed that the ratio of feed per tooth (fz) to radial depth of cutting (ae) for obtaining minimum surface roughness is related to the ratio of diameter (D) to corner radius (r) of ball-nose end miller. Finally, in terms of the minimum surface roughness, a mathematical model is established with consideration of corner radius and diameter of ball-nose end miller. This research indicates that proper selection of cutting parameters (fz and ae) with consideration of diameter and radius corner of ball-nose end miller is a novel avenue for acquiring desired surface roughness. [ABSTRACT FROM AUTHOR]