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USP280 End Mills Series
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Surface roughness is measured in tool feed direction as well as in step-over or pitch direction. The formulae to calculate the theoretical cusp height (peak-to-valley) values are as follows:
For practical purposes, the width and length of the “bites” cut by each tooth of a ball nose tool per one cutter revolution should be equal and the surface should appear like the squares in a chessboard. If this condition exists, the elevated points known as “cusps” are equally distributed and make manual polishing easier. In some cases polishing can be eliminated altogether. The concept was first introduced by Makino Milling Machine Company as “Feed = Pitch” or “f=P”. It is illustrated in picture 36A below. This condition is achieved when the feed per tooth (fz) equals the pitch or step-over (ae): fz = ae. Advantages are the shortest machining cycle to achieve the desired finish, a smooth, multi-directional surface finish that is easy to polish, and increased geometrical accuracy and repeatability. Stiff, sharp tools with minimal run-out are a requirement to achieve good finish results.
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