Influence of cutter width on surface roughness and cutter run out during horizontal milling operation

Abstract EN

This work focuses on studying the effect of cutter width on the surface roughness and cutter run out during horizontal milling operation, since the contact width in milling operations depends on the cutter geometry, especially (cutter diameter and width).

So, three types of helical plain cutters with different widths are taken, (40,63,80mm), used in horizontal milling , when other cutter geometry parameters are constant.

As for workpiece material, it was from (structural steel (1.0402)) according to (DIN:C22) specifications, with different cutting conditions (spindle speed, feed rate, and depth of cut) for each cutter, results show that milling cutter, which has larger width (80mm), gives large surface roughness and cutter runout compared with other two types.

The results show that the surface roughness and cutter runout decrease with the increase of spindle speed under constant feed rate and depth of cut.

While surface roughness and cutter runout increase with increase of feed rate for constant spindle speed and depth of cut .Both the results of fixing spindle speed and feed rate with changing depth of cut show that surface roughness and cutter runout increase with the increase of depth of cut .In addition, cutter runout has a large effect on the surface roughness because it causes an increase in surface roughness of workpiece.

Also surface roughness decreases at cutter (80mm width) which causes larger surface roughness than cutters (63mm and 40mm width),.

For certain machining parameter as the spindle speed increases from (100 to 210 rpm), feed rate (35 mm/min) and depth of cut (0.1mm), the surface roughness value decreases from (1.61333 to 1.418333) μm at cutter (80mm width.) .When the cutter (63mm width) is used, the surface roughness decreases from (1.5222 to 1.3182) μm , and at cutter (40mm width) the surface roughness decreases from (1.4111 to 1.212) μm.

Also in this study, multiple linear regression model is used within (SPSS) software to predict the experimental data for each surface roughness and cutter runout for different three cutters and results show from comparing between predicted and measured values that-(SPSS) software gives high prediction accurate