The present investigation is the influence of limited reinforcement of fly ash (5 wt%) effects on surface roughness. In this regard, the fly Ash reinforced aluminium alloy (AA7475) composite was prepared and machined and measured the surface roughness to compared to aluminium alloy (AA7475). The sample size is 32 (16 for each tool) with 95% CI pre-test power 80% was used. The surface grinding operation is used to remove surface abnormalities. These pieces are machined in specific contour milling and are performed with different tools. Machined specimens are tested using a profilometer for calculating surface roughness and it was performed according to ASTM D3039 standards. The findings suggested that the plain aluminium alloy (AA7475) had a surface roughness of 0.51 mm and the composite aluminium alloy (AA7475) reinforced with 5 wt% fly ash had a surface roughness of 0.38 mm. The statistical value analysis yielded a significance value of 0.034 (p>0.05), indicating that there was substantial variation across the groups. In this research investigation, it was found that the surface roughness of a composite made of a 5 wt% fly ash augmented aluminium alloy (AA7475) was 32.27% lower than that of a plain aluminium alloy.

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