A first approach to characterize the surface integrity generated by ball-end finishing milling

A simplified procedure is proposed to predict the surface integrity of complex-shape parts generated by ball-end finishing milling. Along a complex cutting path, the tool inclination may vary within a large range. A geometrical study is performed to predict the effect of the tool inclination (lead angle) on the micro-geometry of the machined surface and on the effective cutting speed. This geometrical study brings out a range of values of the lead angle for which the machined surface is damaged by cutting pull-outs. This geometrical study also brings out a range of values of the lead angle for which the effective cutting speed is null. This case corresponds to extreme values of the cutting forces and to high compressive residual stresses. These predictions are verified for a selection of tool inclinations and other cutting parameters such as cutting speed, feed per tooth and cusp height. These machining tests are performed on a high-strength bainitic steel. The experimental campaign includes milling tests with cutting forces measurements, 2-D optical micro-geometry measurements and X-ray diffraction measurements.