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Development of a methodology for prediction of surface rougness of curved cavities manufactured by 5-axes cnc milling

Çelik, Kazım Arda
The surface quality is identified by surface roughness parameters. The average surface roughness (Ra) is used in this study, as it is the most commonly used roughness parameter in the industry. A particular curved cavity of a forging die is selected for the experimental study. Different milling methods are tested. The comparison studies are conducted between 3-axes and 5-axes milling, linear and circular tool path strategies and down and up milling. According to the experimental study, appropriate method is determined for the milling of a particular curved cavity of a forging die. The experimental analysis based on design of experiments (DOE) has been employed by considering cutting speed, feed per tooth and stepover parameters. Multiple linear regression technique is used by which a mathematical formula has been developed to predict the Ra values for milling parameters. The results of the mathematical formula are controlled by conducting test experiments and good correlations are observed between the results of the formula and the results of test experiments.