This study was conducted to investigate the synergistic effects of cutting parameters on surface roughness in ball end milling of oxygen-free high conductivity (OFHC) copper and to determine a statistical model that can suitably correlate the experimental results. Firstly, an experimental plan based on a full factorial rotatable central composite design with variable parameters, the cutting feed rate or feed per tooth, axial depth of cut, radial depth of cut, and the cutting speed, was developed. The range for each variable was varied through five different levels. Secondly, a mathematical model was formulated based on the response surface methodology (RSM) for roughness components (Ra and Rz micron). The predicted values from the model were found to be close to the actual experimental values. Finally, for checking the adequacy of the models, analysis of variance (ANOVA) was used to examine the dependence of the process parameters and their interactions. The developed model would assist in selecting the cutting variables for optimization of ball end milling process for a particular material. Based on the results from this study, it is concluded that the step over or radial depth of cut have a higher contribution (45.81%) and thus has a significant influence on the surface roughness of the milled OFHC copper.

中文翻译：

---

响应面法在OFHC铜球头铣削表面粗糙度预测和建模中的应用

进行这项研究以研究切削参数对无氧高电导率（OFHC）铜的球头铣削中表面粗糙度的协同效应，并确定可以适当关联实验结果的统计模型。首先，制定了一个实验计划，该计划基于可变参数的全因子可旋转中央复合材料设计，切削进给速率或每齿进给量，轴向切削深度，径向切削深度和切削速度。每个变量的范围在五个不同级别中有所不同。其次，基于响应表面方法（RSM）为粗糙度分量（Ra和Rz微米）建立了数学模型。发现该模型的预测值接近实际实验值。最后，为了检查模型的充分性，方差分析（ANOVA）用于检查过程参数及其相互作用的依赖性。开发的模型将有助于选择切削变量，以优化特定材料的球头铣削工艺。根据这项研究的结果，可以得出结论，跨步或径向切削深度有较高的贡献（45.81％），因此对铣削OFHC铜的表面粗糙度有重大影响。