Nickel-based alloys (Nimonic 90) are one of the most used materials for aircraft parts, gas turbine components and fasteners due to their inherent properties such as high strength at elevated temperature, good corrosion resistance, high stability, high wear resistance and low thermal conductivity. Because of the above-mentioned properties, Nimonic 90 alloy is difficult to machine, and the roughness obtained by machining of nimonic alloy is comparatively rough. The existing theoretically developed mathematical equations for roughness measurement do not consist of all the machining parameters. It lacks some of the effective roughness parameters such as depth of cut, spindle speed and cutting-edge angle. This article proposes a novel mathematical/geometrical model for the prediction of surface roughness using fundamental geometrical properties of tool and workpiece. For developing the mathematical model, the nose radius of the cutting tool insert is assumed as a straight line (arc length). The principal cutting-edge angle is introduced in the geometrically developed novel model. The developed mathematical/geometrical model comprises mainly depth of cut, principal cutting-edge angle, nose radius, spindle speed and feed. In micro turning, surface roughness increases with an increase in feed and depth of cut. A rough surface, compared to conventional turning, is produced while micro turning due to edge ploughing and rubbing when the chip thickness is lesser than the edge radius. This model is validated by conducting micro-turning experiments on nickel-based superalloy (Nimonic 90) using aluminium titanium nitride physical vapour deposition coated tungsten carbide micro inserts. The surface roughness is significantly affected when the cutting-edge comes in contact with the workpiece; it is because of the imperfect geometry of the nose of the cutting tool. A slight variation of surface roughness with the depth of cut has also been observed. A good correlation is observed between the predicted and experimentally measured roughness values.

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