ARTICLE IN PRESS

International Journal of Machine Tools & Manufacture 46 (2006) 13951402

www.elsevier.com/locate/ijmactool

The statistical modeling of surface roughness in high-speed

at end milling
Babur Ozcelika,, Mahmut Bayramoglub
a

Department of Design and Manufacturing Engineering, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey
b
Department of Chemical Engineering, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey
Received 19 August 2005; received in revised form 26 September 2005; accepted 4 October 2005
Available online 14 November 2005

Abstract
Surface roughness is one of the most important requirements in machining process. The surface roughness value is a result of the tool
wear. When tool wear increase, the surface roughness also increases. The determination of the sufcient cutting parameters is a very
important process obtained by means of both minimum surface roughness values and long tool life. The statistical models were
developed to predict the surface roughness.
This paper presents the development of a statistical model for surface roughness estimation in a high-speed at end milling process
under wet cutting conditions, using machining variables such as spindle speed, feed rate, depth of cut, and step over. First- and secondorder models were developed using experimental results of a rotatable central composite design, and assessed by means of various
statistical tests. The highest coefcient of correlation (R2adj) (88%) was obtained with a 10-parameter second-order model. Meanwhile, a
time trend was observed in residual values between model predictions and experimental data, reecting the probable effect of the tool
wear on surface roughness. Thus, in order to enhance the estimation capability of the model, another independent variable was included
into the model to account for the effect of the tool wear, and the total operating time of the tool was selected as the most suitable variable
for this purpose. By inserting this new variable as a linear term into the model, R2adj was increased to 94% and a good t was observed
between the model predictions and supplementary experimental data.
In this study, it was observed that, the order of signicance of the main variables is as X 5 4X 3 4X 4 4X 1 4X 2 (total machining time,
depth of cut, step over, spindle speed and feed rate, respectively).
r 2005 Elsevier Ltd. All rights reserved.
Keywords: Flat end milling; Surface roughness; Operating time; Cutting parameters; Tool wear; Statistical model

1. Introduction
Surface roughness is one of the most important
requirements in machining process. The surface roughness
value is a result of the tool wear. When tool wear increase,
the surface roughness also increases. The determination of
the sufcient cutting parameters is a very important
process by means of obtained both minimum surface
roughness values and long tool life. The statistical models
were developed to predict the surface roughness.
Corresponding author. Tel.: +90 262 605 18 07;
fax: +90 262 605 17 55.
E-mail address: ozcelik@gyte.edu.tr (B. Ozcelik).

0890-6955/$ - see front matter r 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2005.10.005

In end milling, there are many parameters such as the

tool geometry including the tool nose radius and ank
width, run-out error and other parameters (cooling oil,
cutting method), [1], and various cutting conditions
including the feed rate, depth of cut and cutting speed
affecting the surface roughness Ra. In addition to these
variables, Ra is also affected by tool life indicators such as
tool wear and tool edge fracture. Developing predictive
models needed to calculate the optimum cutting conditions
for minimum surface roughness is a necessary but time and
money consuming task, and all the variables cited above
must be considered in the experimental plan. The changing
of the tool with a new one after each run is a very
cumbersome and expensive operation. Thus, assessing the

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B. Ozcelik, M. Bayramoglu / International Journal of Machine Tools & Manufacture 46 (2006) 13951402

1396

Nomenclature
AISI
X

American Iron and Steel Institute

operational variable

effects of all the variables in the same research project

seems to be a more useful way from practical and economic
points of view.
Various studies have been made on the surface roughness
in end milling using different materials, cutting tools, and
experimental and optimization methods. Baek et al. [2]
selected the optimal feedrate using a bisection method.
Peigne et al. [3] studied effects of the cutting vibratory
phenomena and their impacts on the surface roughness of
the machined surface. Franco et al. [4] developed a
numerical model for predicting the surface prole and
surface roughness in face milling with round insert cutting
tools. Kishawy et al. [5] researched the effect of ood
coolant, and dry cutting, on tool wear, surface roughness
and cutting forces. Antonio Maria de Souza Jr. et al. [6]
examined two face milling cutter systems in high-speed
cutting of gray cast iron under a determined cutting
condition. Tansel et al. [7] were calculated optimal operating
conditions to obtain the best possible compromise between
the roughness of machined mould surfaces and the duration
of nishing cut using GONNS. Ryu et al. [8] studied plane
surface generation mechanism in at end milling using a at
end mill. Mantle and Aspinwall [9] studied the surface
integrity produced by end mill tool using a Taguchi
orthogonal array. Wang and Chang [10] analyzed the
inuence of cutting conditions and tool geometry on surface
roughness during slot end milling. Lou and Chen [11]
described a new approach for recognition systems to predict
surface roughness. Tsai et al. [12] developed an in-processbased recognition system to predict the surface roughness of
machined parts in the end milling process. Ertekin et al. [13]
identied the most inuential and common sensory features
for dimensional accuracy and surface roughness in CNC
milling operations using three different material types. Fuht
and Wu [14] studied the inuence exerted by the tool
geometries and cutting conditions on machined surface
quality and were able to build a model predicting the surface
quality for 2014 aluminum. Lanz et al. [15] investigated the
effects of machining parameters on the material removal
mechanism, machining forces, surface texture and work
piece breakout. Dabade et al. [16] discussed analysis of the
cutting process performed using a face-milling cutter
mounted with self-propelled round inserts designed and
fabricated in their work.
Different neuro fuzzy inference and articial neural
network systems have been widely used for the selection of
the operating conditions in machining operations. Dweiri
et al. [17] modelled the down milling machining process of
Alumic-79 using an adaptive neuro fuzzy inference system
to predict the effect of machining variables such as spindle

R 2%
R2adj%
S
Ra

coefcient of multiple correlation

adjusted coefcient of multiple correlation
error standard deviation
surface roughness

speed, feed rate, depth of cut and number of utes on the

surface nish. Lo [18] used an adaptive network-based
fuzzy inference system (ANFIS) to predict the surface
roughness from an end milling process. An articial neural
network was used for feature selection in order to estimate
ank wear and surface roughness during the face milling
operation by Saglam and Unuvar [19]. Benardos and
Vosniakos [20] used a neural network modelling approach
for prediction of surface roughness Ra in CNC face milling.
Balic and Korosec [21] predicted average mean roughness,
Ra using neural network (NN). Ozcelik et al. [22]
determined optimum cutting parameters of Inconel 718
to enable minimum surface roughness under the constraints of roughness and material removal rate by
coupling neural network model and genetic algorithm.
A lot of analytically methods were also developed and
used for predicting surface roughness. El-Wahab and
Kishawy [23] developed mathematical models to improve
the surface quality during CNC machining. Axinte and
Dewes [24] presented experimental results and corresponding empirical models for workpiece surface integrity (SI)
during high-speed machining. The equations concerning the
surface roughness were explained by Shaw [25]. Baek et al.
[1] developed a mathematical model including the static and
dynamic components of the cutting process for surface
roughness prediction in face milling. Lee et al. [26] suggested
a simulation algorithm and programming method to
simulate the machined surface using an acceleration signal
in high-speed end milling. Alauddin et al. [27] presented the
development of mathematical models for tool life in end
milling steel using high-speed steel slot drills under dry
conditions. Benardos and Vosniakos [28] aimed a review of
the various methodologies and practices that are being
employed for the prediction of surface roughness. Fang and
Sa-Jahanshahi [29] presented a new algorithm to establish
a reference tool-based model for predicting surface roughness through the correlation analysis and regression method.
In the literature, the effect of the different parameters on
the surface roughness was researched. In this study, spindle
speed, feed rate, depth of cut and step over as machining
conditions were selected. A statistical model was developed
using these cutting parameters. In order to enhance the
estimation capability of the model, another independent
variable was included into the model to account for the effect
of the tool wear and the total operating time of the tool was
selected as the most suitable variable for this purpose.
This paper presents the development of a statistical
predictive model for surface roughness in high-speed at
end milling process under wet cutting conditions using
machining variables such as spindle speed, feed rate, depth

ARTICLE IN PRESS
B. Ozcelik, M. Bayramoglu / International Journal of Machine Tools & Manufacture 46 (2006) 13951402

of cut, step over, and total operating time as a new variable

reecting the effect of the tool wear, indirectly, but in a
simple way, without the need for the measurement of the
tool wear after each run.
2. Experimental work
2.1. Workpiece material, cutting tools and equipment
The experimental study was carried out in wet cutting
conditions on a DECKEL MAHO DMU 60 P ve-axis,
high-speed CNC milling machine equipped with a maximum spindle speed of 12,000 rpm, feed rate of 10 m/min
and a 15-kW drive motor. CNC part programs for tool
paths were created. The workpiece material used was AISI
1040 steel in the form of a 60 mm
60 mm
40 mm block.
Tables 1 and 2 provide detailed information on chemical
composition and mechanical properties of this AISI 1040
steel. A at end mill (10 mm diameter, 451 helix angle,
TiAlN coated solid carbide, 4-utes) produced by Sandvik
(R216.34-10045-AC22N 1620) was used in the tests. The up
milling cutting method and compressed cooling oil as the
cutting environment were used. The same tool was used
until maximum ank wear reached VBmax 0.1 mm.The
setup of the workpiece and at end mill is shown in Fig. 1.

1397

step over. Thus, a minimum of 16 runs is required to

develop a full second-order model. Meanwhile, plans with
some highly desirable properties such as rotatability,
orthogonal or uniform precision require more runs.
Among various designs, the rotatable central composite
design has the most popular promising outstanding
benets [30,31]. In this study, a rotatable central composite
(uniform precision) design with six central replicates was
selected, with ve different levels for each variable, as
shown in Table 3. Variable ranges were determined on the
basis of a cutting tool catalog. As presented in Table 4, the
experimental plan was composed of a full 24 factorial with
four central replicates (runs 120), augmented by eight
axial runs with two central replicates (runs 2130) to
estimate second-order effects. For the selection of the best
model, the adjusted coefcient of multiple correlations,

2.2. Surface roughness measurement

Surface roughness Ra was measured using a portable
Mitutoyo Surf Test 301. A minimum of 10 measurements
in the traverse direction were taken, the highest and lowest
values were discarded and the average value was recorded.
In this study, Ra values were measured between 0.55 and
2.74 mm. The repeatability of the measurements was found
to be in the range of 25%, which was considered
satisfactory for generating empirical models.
3. Experimental design
In this study, the experimental plan has four controllable
variables namely, spindle speed, feed rate, depth of cut and

Table 1
Chemical composition of material (wt %) AISI 1040 steel
C

Si

Mn

0.39

0.24

0.71

0.02

0.03

Fig. 1. Schematic representation of workpiece and at end mill.

Table 2
Mechanical properties of material
Workpiece material

UTS (MPa)

YS (MPa)

Density kg/m3

Elongation (%)

Hardness (Hb)

AISI 1040

515

350

7845

25

170

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1398

Table 3
Variable levels used in the experimental plan

Table 5
Experimental results

Variable/code

Run no.

Surf. roughness
(mm) Ra

Mach. time
(min) t

Total mach. time

(min) T (X5)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

0.76
0.86
1.26
2.57
1.09
1.20
0.55
0.68
0.70
1.04
2.74
1.13
0.73
1.30
1.75
0.66
1.23
0.57
1.43
0.83
1.27
0.91
2.10
0.87
1.81
0.74
1.29
2.08
1.32
1.22

1.30
1.30
1.28
0.72
2.45
1.28
2.45
1.53
1.53
0.72
1.53
0.72
2.45
1.28
0.72
1.30
1.28
1.53
1.30
2.45
1.28
1.28
1.00
3.68
1.28
1.28
1.28
1.28
0.83
2.92

1.30
2.60
3.88
4.60
7.05
8.33
10.78
12.31
13.84
14.56
16.09
16.81
19.26
20.54
21.26
22.56
23.84
25.37
26.67
29.12
30.40
31.68
32.68
36.36
37.64
38.92
40.20
41.48
42.31
45.23

Spindle speed (rpm) X1

Feed rate (mm/min) X2
Depth of cut ( mm) X3
Step over (mm) X4

Levels
2

1

4000
640
0.1
1

5500
1320
0.3
2

7000
2240
0.5
3

8500
3400
0.7
4

10 000
4800
0.9
5

Table 4
Second-order rotatable central composite design
Exper. no.

Spindle speed
(rpm) X1

Feed rate
(mm/min) X2

Depth of cut
(mm) X3

Step over
(mm) X4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

8500
5500
7000
5500
5500
7000
8500
8500
5500
8500
5500
5500
5500
7000
8500
8500
7000
8500
5500
8500
7000
10 000
7000
7000
7000
7000
7000
4000
7000
7000

1320
1320
2240
3400
1320
2240
1320
3400
3400
3400
3400
3400
1320
2240
3400
1320
2240
3400
1320
1320
2240
2240
4800
2240
2240
2240
2240
2240
2240
640

0.7
0.3
0.5
0.7
0.7
0.5
0.3
0.7
0.3
0.3
0.7
0.3
0.3
0.5
0.7
0.3
0.5
0.3
0.7
0.7
0.5
0.5
0.5
0.5
0.9
0.1
0.5
0.5
0.5
0.5

4
4
3
4
2
3
2
2
2
4
2
4
2
3
4
4
3
2
4
2
3
3
3
1
3
3
3
3
5
3

variables namely, spindle speed, feed rate, depth of cut and

step over are considered. In the second part, total
machining time is inserted as a new variable into the
model. The following notation is used in tables and model
equations:
X 1 2X 5 main effects (spindle speed, feed rate, depth of cut,
step over and total machining time, respectively),
X 6 2X 9 quadratic effects X 6 X 21 ; X 7 : X 22 ; X 8 : X 23 ;
X 9 : X 24 ,
X 10 2X 15 interaction effects X 10 X 1 X 2 ; X 11 X 1 X 3 ; X 12
X 1 X 4 ; X 13 X 2 X 3 ; X 14 X 2 X 4 ; X 15 X 3 X 4 .

R2adj, was considered:

R2adj 1  n  11  R2 =n  p,

(1)

where; R2 is the usual coefcient of multiple correlation, n

is the data size and p is the number of parameter. Statistical
calculations and analysis were undertaken using the
Minitab 13.1 software.
4. Results and discussion
The results of the experimental design are shown in
Table 5. In the rst part of the modelling study, four

4.1. Preliminary modelling

Regression results for rst- and second-order models are
presented in Table 6. For rst-order model, the rst part of
the design (20 runs) was used, while for full second-order
model, regression analysis was applied to the complete
design of 30 runs. First-order and full second-order models
were not found sufciently adequate to represent the
experimental data; R2adj of the full second-order model was
equal to 84.4%.

ARTICLE IN PRESS
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1399

Table 6
First- and second-order models regression results
Model

Number of
variables

Number of
data points

R2%

R2adj%

First order
First order+interaction
Second order

4
10
14

20
20
30

74.3
94.0
91.9

67.4
87.3
84.4

0.329
0.205
0.217

Table 7
Best subsets regression analysis results
Number of
vars.

R2 (%)

R2adj (%)

X
1

4
5
6
7
8
9
10
11
12
13
14

85.3
87.6
89.2
90.3
91.0
91.7
91.8
91.8
91.9
91.9
91.9

83.0
85.0
86.4
87.2
87.5
87.9
87.5
86.8
86.1
85.3
84.4

0.226
0.212
0.202
0.196
0.194
0.191
0.194
0.199
0.204
0.210
0.217

10

11

12

*
*
*
*
*
*
*
*
*
*
*

*
*
*
*

*
*
*
*

*
*
*
*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*

*
*
*

*
*
*
*
*
*
*
*

*
*
*
*
*

13

14

15

*
*
*
*
*
*
*

*
*
*
*
*
*

*
*

With the goal of better models, the best subsets

regression analysis was applied to the complete combinations of the full 15 terms, including the main effects,
interactions and pure second-order effects. The results are
represented in Table 7. Thus, the Model A with nine terms
was found as the best one, with R2adj equal to 87.9%:
Model A
Ra  1:61 2:22e  04X 1 4:35X 3 0:544X 4
 1:16X 8  0:0912X 9  5:00  08X 10
 5:42e  04X 11 9:76e  04X 13
5:20e  05X 14 .

On the other hand, among the various statistical tests

performed with Model A, residual analysis detected a clear
pattern in the standardized residuals versus run order plot,
as seen in Fig. 2. A trend was observed in the residual
values with the consequence that the model underestimated
surface roughness values as the experiment progressed. As
the same tool was kept during the entire experimental plan,
it was concluded that this time trend was due to the tool
wear which progressed with time and affected more and
more negatively the surface roughness. Thus it was decided
to include a new variable in the model to suppress the effect
of the tool wear on the surface roughness.
4.2. Model improvement
In the absence of any theoretical model, the simplest way
to correlate the surface roughness to the tool wear is by

Fig. 2. Standardized residual versus observation order for Model A.

means of a linear model. On the other hand, tool wear is a

dynamic process. It is related to the machining conditions,
as well as to the total machining time. At constant operating
parameter values, a relation is expected between tool wear
and time. In this study, the values of the operating variables
change from run to run, according to the experimental plan.
So, a complicated term which accounts for the tool wear
must be included into the model, making the regression
analysis difcult. Various terms were tested for this purpose,
and the total machining time was found as the most simple
and suitable variable expressed as the sum of the machining
times of the runs executed before the jth run:
T j Sti .

(3)

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1400

Table 8
Regression analysis results
Model

Number of variables

Number of data points

R2 (%)

R2adj (%)

First order
First order+interaction
Second order

5
11
15

20
20
30

74.8
95.0
96.3

68.0
88.0
92.3

0.331
0.200
0.152

Table 9
Best subsets regression analysis results with total operating time as a new variable
Number of
var.

R2 (%)

R2adj (%)

X
1

4
5
6
7
8
9
10
11
12
13
14
15

85.4
89.8
92.2
93.5
94.6
95.3
96.0
96.2
96.2
96.2
96.3
96.3

83.1
87.7
90.1
91.4
92.5
93.1
93.8
93.8
93.5
93.2
92.8
92.3

0.225
0.192
0.172
0.160
0.150
0.144
0.136
0.137
0.140
0.143
0.147
0.152

*
*
*
*
*
*

*
*
*
*
*
*
*
*
*

*
*
*
*
*
*

5
*
*
*
*
*
*
*
*
*
*
*
*

*
*
*
*

*
*

*
*
*
*
*
*
*

10

11

*
*
*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*
*
*
*
*

12

*
*
*
*
*
*
*
*
*

13

14

15

*
*
*
*
*
*
*
*
*
*
*
*

*
*
*
*
*
*
*
*

*
*
*

Regression analysis results are given in Table 8. When

compared with Table 6, improvements are observed in the
R2adj values with the best improvement for the second-order
model. For possible further improvement, best subsets
regression analysis was performed, with the results given
in Table 9. Model B with 10 terms was found as the best
model:
Model B
Ra  1:80 2:19e  04X 1 4:13X 3 0:58X 4
8:67e  03X 5  1:23X 8  0:0965X 9  6:00e
 08X 10  5:21e  04X 11 1:05e  03X 13
5:20e  05X 14 .

Other statistical tests conrmed also the superiority of

Model B over Model A. The standardized residual versus
observation order plot, as shown in Fig. 3, does not exhibit
the time trend detected in Fig. 2. When the orders of entry
of the variables into the best subset models given in Table 9
are observed, it is observed that, the order of signicance of
the main variables is as X 5 4X 3 4X 4 4X 1 4X 2 . X 2 is the
least signicant and so it is absent in Model B. Among
interaction terms, X 1 X 2 ; X 1 X 3 and X 2 X 3 appear to be
highly signicant and ranked after X 5 . On the other hand,
as seen in Fig. 4, the ts between experimental surface
roughness values and model surface roughness values are
very good. Finally, to test further Model B, eight new
experiments with the same tool were conducted and
represented in Table 10. The standard error between
experimental values and model values was calculated as

Fig. 3. Standardized residual versus observation order for Model B.

Fig. 4. Experimental versus tted Ra for Model B.

ARTICLE IN PRESS
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1401

Table 10
Test runs
Run. no

Spindle speed
(rpm)

Feed rate (mm/

min)

Depth of cut
(mm)

Step over
(mm)

Total mach. time

(min)

Ra experiment
(mm)

Ra Model B
(mm)

1
2
3
4
5
6
7
8

8500
8500
8500
5500
8500
5500
7000
5500

1320
1320
1320
1320
1320
1320
2240
3400

0.3
0.1
0.7
0.3
0.3
0.7
0.5
0.3

4
1
4
4
2
2
3
2

46.5
58.5
65.8
67.1
69.6
73.6
74.9
76.4

0.97
0.45
1.15
1.44
1.00
1.55
1.66
1.50

1.05
0.54
1.16
1.28
1.11
1.77
1.76
1.43

0.134 sufciently low to conrm the high predictive power

of Model B.
5. Conclusion
This paper presents a model developed by response
surface methodology for predicting surface roughness in
high-speed at end milling processes under wet cutting
conditions. In experimentation, a rotatable central composite design with 30 runs was used to develop empirical
models with spindle speed, feed rate, depth of cut and step
over as machining variables. Various statistical tests and
analyses were performed to select the best model and the
highest R2adj obtained was 87.9% with Model A containing
nine terms. By the inclusion of the total operating time as a
new variable into Model A, R2adj was increased to 94%. The
predictive power of this model was tested with supplementary experimental roughness data and a good t was
observed.
By insertion of the total operating time into the model in
order to reect the effect of the tool wear on surface
roughness, it was possible to use the same tool during the
experimentation, (until maximum ank wear of VBmax
0.1 mm). In this way, the measurement of the tool wear
after each run was bypassed and the time consumed during
the experimentation was shortened.
The standard error between experimental values and
model values was calculated as 0.134 sufciently low to
conrm the high predictive power of Model B.
In this study, it was observed that, the order of
signicance of the main variables is as X 5 4X 3 4X 4 4
X 1 4X 2 (total machining time, depth of cut, step over,
spindle speed and feed rate, respectively).
Acknowledgement
The authors would like to thank the Gebze Institute of
Technology for supporting this project (01-B-03-04-10).
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