Texture formation model for end milling surface

During the machining process, surface quality control is a critical factor, as surfaces are the starting point for many defects in engineering parts, including tearing, cracking, and corrosion. Surface roughness is a crucial aspect of the machining process as it is used to calculate and assess the quality of the part. A variety of methods have been used to estimate surface roughness. Most methods and techniques, however, concentrate more on predicting surface roughness and finding the best machining parameters to achieve the finest surface roughness. There is a lack of information as to why and how the selected machining parameters achieve the best surface roughness. Hence it is crucial to look for a new tool that can provide a stronger insight into the formation of surface roughness before the machining process. This research aims to discover the consequence of variable spindle speed on surface forming during the end milling process through a simulation model. The model is generated by simulation using the MATLAB algorithm programmer software with a spindle speed set for the simulation model of 1000rpm, 1500rpm, 2000rpm, 2500rpm, 3000rpm, 3500rpm and 4000rpm with a constant cutting speed and the depth of cut. The analysis results on the segmented area between tool cutting edges trajectories showed a similar trend to surface roughness in actual machining, especially the analysis results from the mean and standard deviation of segmented area, where there were showing possible saturation point around 3000 to 4000 rpm, indicates that the established theory from this study is worth to be explored further.