The Dependence of 3D Surface Roughness Parameters on High-Speed Milling Technological Parameters and Machining Strategy

Abstract

High-speed milling is an effective machining method extensively used in modern material processing. This machining method offers increased efficiency, quality and accuracy of the machined surface as well as considerably reducing overall production costs and machining time. This paper outlines comprehensive research into the impact of the technological strategy and processed materials on carefully selected 3D surface roughness parameters. This research provides manufacturers who use high-speed milling with recommendations on how to better obtain the desired surface roughness parameters. More specifically, it covers multifactorial analysis of the following factors: feed rate, manufacturing strategy, overlap and material influences on the most characteristic 3D surface parameters. The results are based on ANOVA – analysis of variance, where differences between groups of means are analysed using a range of statistical models. Subsequent analysis and respective conclusions identify the most significant factors as being the material and high-speed milling manufacturing strategy. Analytically justified recommendations for manufacturers regarding the preferred high-speed milling strategies are provided. The research concluded that the values of the selected 3D surface roughness parameters in high-speed milling depend significantly on the type of material being machined, milling mode and cutting tool overlap as well as feed. In particular, Sa - the arithmetic mean height, is highly sensitive to the milling mode.

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