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 ( f z ) to radial depth of cutting ( a e ) 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 ( f z and a e ) with consideration of diameter and radius corner of ball-nose end miller is a novel avenue for acquiring desired surface roughness.