Monitoring and Prediction of Surface Roughness in Ball End Milling with Air Blow Application

TL;DR: In this article, the authors investigated the relations of the cutting conditions and the various air blow applications which affect the surface roughness and determined the suitable cutting condition for the aluminum (Al6063) with the ball end milling by utilizing the response surface analysis referring to the minimum surface Roughness.

Abstract: This paper presents the additional work of the previous research in order to investigate the relations of the cutting conditions and the various air blow applications which affect the surface roughness. The suitable cutting condition is determined for the aluminum (Al6063) with the ball end milling by utilizing the response surface analysis referring to the minimum surface roughness. The cutting force is monitored during the cutting to analyze the surface roughness. The dynamometer is employed and installed on the table of 5-axis CNC maching center to measure the in-process cutting force. The models of surface roughness and cutting force are calculated by using the multiple regression analysis with the least squared method at 95% significant level. The experimentally obtained results showed that the surface roughness can be well explained by the in-process cutting force. The prediction accuracy and the prediction interval have been presented to verify the obtained surface roughness model at 95% confident level.