Redefinition of precision in finishing milling: Exploring the influence of tool margin and edge micro-radius on surface roughness

Abstract

This article presents an analysis of microgeometry parameters, specifically the radius of cutting edge rounding, margin width, and rake angle influence on surface roughness in the milling of 7075 alloy. The study is underpinned by a set of 243 cutting tests conducted using 27 mills, each with a unique combination of geometry, feed, and radial infeed. Experimental mathematical models of the roughness parameters were developed. The findings reveal that while the influence of the cutting edge rounding radius on surface roughness is nonlinear and non-monotonic, the margin width has a monotonic effect and is the most significant factor impacting roughness.