3198


FACTA UNIVERSITATIS  
Series: Mechanical Engineering Vol. 20, No 1, 2022, pp. 157 - 165 

https://doi.org/10.22190/FUME180220002S 

© 2022 by University of Niš, Serbia | Creative Commons License: CC BY-NC-ND 

Original scientific paper 

INFLUENCE OF THE CUTTING PARAMETERS ON FORCE, 

MOMENT AND SURFACE ROUGHNESS IN THE END MILLING 

OF ALUMINUM 6082-T6 

 

Jelena Stanojković, Miroslav Radovanović 

Faculty of Mechanical Engineering, University of Niš, Serbia 

Abstract. In this paper the performances, i.e. cutting force, moment and surface 

roughness, in the end milling of aluminum 6082-T6 with solid carbide end mill were 

measured and analyzed for different values of the cutting parameters: number of 

revolutions, feed rate and depth of cut. The cutting force and moment were measured 

using a Kistler piezoelectric dynamometer. Surface roughness was measured using a 

Mahr profilometer. The results were analyzed in the Minitab 17 software package, in 

order to determine the influence of the given factors on the performances and modeling 

of the milling process. 

Key Words: Cutting Force, Moment, Surface Roughness, Aluminum 

1. INTRODUCTION  

The cutting force, moment and surface roughness are the most important indicators of 

machinability of materials and are very significant for the theory of cutting processes. 

By separating the cutting layer from the machining surface, the cutting edge of the 

cutting tool encounters the force. This force removes a layer of material and separates it 

from the workpiece in the form of chips. Depending on the machining conditions, the 

magnitude of force can vary widely. The force is the main indicator of wear control, the 

quality of the machined part, and the shape of chips and vibrations. Knowing the cutting 

force enables one, among other things, to determine the energy balance of the machine 

tool, do the calculation and dimensioning of the elements of the kinematic system of machine 

tool, do the calculation and dimensioning of the cutting tool, optimize the machining process 

and enhance the efficiency of the process based on the calculation of the optimal values of the 

cutting parameters [1]. The force can be determined by measuring the components by the 

dynamometer. 

 
Received February 20, 2018 / Accepted November 20, 2018 

Corresponding author: Jelena Stanojković  
Faculty of Mechanical Engineering, University of Niš, A. Medvedeva 14, 18000 Niš, Serbia 

E-mail: jstanojkovic@masfak.ni.ac.rs 



158 J. STANOJKOVIĆ, M. RADOVANOVIĆ 

The force components in the end milling process can be decomposed into [2]: 

▪ Fc-cutting (tangential) force, 
▪ Ff-feed (radial) force, and 
▪ Fp-thrust (axial) force. 
The machined surface quality is evaluated by surface roughness of the machined part 

and it is one of the most significant product quality characteristics [3, 4]. Surface roughness 

depends on the cutting conditions, especially the form of cutting tools, tool wear, deposits, 

vibration, etc. The basic parameters for monitoring surface roughness are: 

▪ Ra-arithmetic average of the absolute values, 
▪ Rz-medium unevenness depth, and 
▪ Rmax-maximum unevenness depth. 
Milling achieves surface roughness from N5 to N12 with the arithmetic average of 

absolute values Ra of 0.4 to 50 μm, respectively. 

The experimental measurement of cutting force and surface roughness in the milling 

process has been investigated by a large number of researchers and so has the application 

of analytical methods for modeling. One of the most important analytical models of the 

cutting force was created by Kienzle and Victor [5] in the 1950s. Ganesh Babu [6] 

investigated the effects of the cutting parameters (cutting speed, feed rate and depth of 

cut) on the cutting force during end milling of AlSiC metal composite material using the 

Response Surface Methodology (RSM). The experiment was conducted using a four teeth 

high-speed steel end milling cutter with 10 mm in diameter on the vertical milling machine. 

The cutting forces were measured with a Kistler piezoelectric dynamometer, type 9257B. 

The cutting forces increased when the depth of cut increased. Tsai [7] investigated the 

influence of the feed per tooth and the tool diameter on the cutting force in milling 

aluminum 6060-T6. The experiment was conducted using a carbide end milling cutter with 

two teeth and with diameters of 12, 16, and 20 mm, the spindle speed of 1000 rev/min and 

the depth of cut of 1 mm, while the feed rate was varied with values of 200, 260, 300, 360 

and 400 mm/min. The cutting forces were measured with a Kistler piezoelectric 

dynamometer, type 9257B. The cutting forces were simulated by the Recursive Least Square 

(RLS) method and compared with the experimental values. Thamban [8] investigated the 

machining parameters (spindle speed, feed rate and depth of cut) during end milling 

aluminum 6061-T6 with coated tungsten carbide and diamond coated end milling cutter with 

10mm in diameter. All the components of the cutting forces were measured with a Kistler 

piezoelectric dynamometer, type 9257B. The cutting force was observed to be increasing 

with depth and feed rate during the end milling for both the cutting tools (coated and 

uncoated). Turgut [9] investigated the effect of machining parameters (cutting speed, feed 

rate and depth of cut) on the cutting force and surface roughness in the face milling 

operation of AlSiC metal matrix composites. The cutting force and surface roughness 

were measured at cutting speeds of 300, 350, 400 and 450 m/min, feed per tooth of 0.1, 

0.15 and 0.20 mm/tooth and depth of cut of 0.5 and 1 mm. The experiment was conducted 

using coated and uncoated milling cutters of 32 mm in diameter on the vertical machining 

center Johnford VMC-850 without using coolant. The cutting forces were measured with 

a Kistler piezoelectric dynamometer, type 9257B. Increasing the feed per tooth and depth 

of cut increased the cutting force for all the cutting conditions, but increasing cutting 

speed decreased the cutting force. The best results of the cutting force were obtained with 

the cutting speed of 400 m/min and the feed rate of 0.1mm/tooth. Jeykumar [10] 

investigated the influence of spindle speed, feed rate and depth of cut on the cutting force, 



 Influence of Cutting Parameters on Force, Moment and Surface Roughness in End Milling 159 
 

tool wear and surface roughness in the end milling operation of Al6061/SiC using the 

Response Surface Methodology. The experiment was conducted using a milling cutter 

with indexable inserts made of tungsten carbide on the milling machine HMT-FNIU. The 

cutting forces were measured using a Kistler piezoelectric dynamometer, type 5070. The 

experimental results were compared with the mathematical model developed using the 

Response Surface Methodology.  

The objective of this study is to determine the influence of the factors (spindle speed, 

feed rate and depth of cut) on the performances (cutting force, moment and surface roughness) 

in the end milling of aluminum alloy 6082-T6. The obtained mathematical model facilitates 

planning the milling process. 

2. EXPERIMENTAL STUDY 

In the experimental measurements of the force, moment and surface roughness in the end 

milling samples of aluminum alloy 6082-T6 were used, with the following dimensions of the 

workpiece: 50x30x400 mm. The chemical composition of the aluminum alloy 6082-T6 is 

given in Table 1. 

Table 1 Chemical composition of Al 6082-T6 

Chemical elements Composition [%] 

Al 95.2-98.3 
Cr 0.25 
Cu 0.1 
Fe 0.5 
Mg 0.6-1.2 
Mn 0.4-1.0 
Si 0.7-1.3 
Ti 0.1 
Zn 0.2 

Others 0.15 

The cutting tool that was used in the experiment was solid carbide end mill 

JS413160D2SZ3.0, manufactured by SECO, Fig 1. The geometry of the end milling 

cutter is given in Table 2 [11]. 

 

Fig. 1 Solid carbide end mill SECO 



160 J. STANOJKOVIĆ, M. RADOVANOVIĆ 

Table 2 Cutting geometry of solid carbide end mill  

Diameter-Dc[mm] 16 

Max depth of cut-ap [mm] 32 

Diameter of tool shrank-dm [mm] 16 

Length of cutting tool- l2 [mm] 100 

Number of teeth- zn 3 

Helix angle- [] 40 

Cutting tool edge angle- [] 90 

Rake angle- [] 20 

For design of the experiment the selected factors of the milling process were spindle 

speed (n), feed rate (Vf) and depth of cut (ap). They were the main factors that influence 

the cutting force, moment and surface roughness. The factors were varied on two levels. 

The levels of factors are shown in Table 3. 

Table 3 Levels of factors 

Factors 
Levels 

-1 0 +1 

Spindle speed-n [rev/min] 320 405 560 

Feed rate-Vf [mm/min] 62 93 175 

Depth of cut-ap [mm] 0.4 0.7 1.2 

The experimental research was carried out on the “Prvomajska” UGH universal 

milling machine, under the laboratory conditions. The force and moment were measured 

with a Kistler piezoelectric dynamometer, type 9123C. The experimental setup is shown 

in Fig. 2. 

 

Fig. 2 Universal milling machine “Prvomajska” UGH 

Surface roughness was measured on a Mahr profilometer under the laboratory conditions, 

Fig. 3. 



 Influence of Cutting Parameters on Force, Moment and Surface Roughness in End Milling 161 
 

 

Fig. 3 Mahr profilometer for measuring surface roughness 

The plan of the experiment and measurement results of force Fc, moment M and 

surface roughness Ra is shown in Table 4. 

Table 4 The plan of the experiment and measurement results 

No. 
n 

[rev/min] 

Vf 

[mm/min] 

ap 

[mm] 

n 

[rev/min] 

Vf 

[mm/min] 

ap 

[mm] 

Fc 

[N] 

M 

[Nm] 

Ra 

[μm] 

1 -1 -1 -1 320 62 0.4 37.3 0.30 2.907 

2 -1 -1 1 320 175 1.2 125.0 0.9 1.600 

3 -1 1 -1 320 62 0.4 98.6 0.76 5.191 

4 -1 1 1 320 175 1.2 211.8 2.42 4.267 

5 1 -1 -1 560 62 0.4 31.6 0.26 1.673 

6 1 -1 1 560 175 1.2 76.7 0.69 1.757 

7 1 1 -1 560 62 0.4 74.6 0.57 3.348 

8 1 1 1 560 175 1.2 174.9 1.45 3.301 

9 0 0 0 405 93 0.7 55.0 0.55 1.945 

10 0 0 0 405 93 0.7 50.0 0.50 1.976 

11 0 0 0 405 93 0.7 60.0 0.58 1.988 

3. ANALYSIS OF RESULTS AND DISCUSSION 

The cutting force, moment and surface roughness measurement results were analyzed 

by using the analysis of variance (ANOVA) in the Minitab 17 software package. 

It is clear from the results of ANOVA that depth of cut (ap) and feed rate (Vf) are the 

dominant factors affecting the cutting force. The factors influencing the force are: spindle 

speed (n), feed rate (Vf), followed by spindle speed (n), while the interaction between 

feed rate and depth of cut (Vfap) and that between spindle speed and depth of cut (nap) are 

also significant. The interaction between spindle speed and feed rate (nVf) and three ways 

interaction (nVfap) is not significant based on the P-value because its value is greater than 

0.1 [12, 13, 14]. F-value is used to determine whether group means are equal, it is just a 

matter of including the correct variances in the ratio. The analysis of variance for the 

cutting force is given in Table 5.  



162 J. STANOJKOVIĆ, M. RADOVANOVIĆ 

Table 5 Analysis of variance for cutting force 

Factors and interactions Sum of square Mean square F-value P-value 

N 1650.3 1650.3 66.01 0.015 

Vf 10461.8 10461.8 418.47 0.002 

ap 14990.5 14990.5 599.62 0.002 

nVf 6.0 6.0 0.24 0.674 

nap 385.0 385.0 15.40 0.059 

Vfap 814.1 841.1 32.56 0.029 

nVfap 110.3 110.3 4.41 0.171 

 

All factors and interactions have a significant effect on the moment. The analysis of 

variance for the moment is given in Table 6.  

Table 6 Analysis of variance for moment 

Factors and interactions Sum of square Mean square F-value P-value 

N 0.24851 0.24851 152.15 0.007 

Vf 1.16281 1.16281 711.93 0.001 

ap 1.59311 1.59311 975.37 0.001 

nVf 0.10351 0.10351 63.38 0.015 

nap 0.11281 0.11281 69.07 0.014 

Vfap 0.28501 0.28501 174.50 0.006 

nVfap 0.04651 0.04651 28.48 0.033 

All factors and interactions have a significant effect on surface roughness. The 

analysis of variance for surface roughness is given in Table 7.  

Factors and interactions Sum of square Mean square F-value P-value 

N 1.8876 1.88762 3834.04 0.000 

Vf 8.3436 8.34561 16947.08 0.000 

ap 0.6017 0.60170 1222.15 0.001 

nVf 0.3750 0.37498 761.63 0.001 

nap 0.6430 0.64298 1305.98 0.001 

Vfap 0.0079 0.0794 16.12 0.057 

nVfap 0.0330 0.03302 67.08 0.015 

Based on the obtained data, the influence of the factors on the cutting force, moment 

and surface roughness in the end milling of aluminum 6082-T6 can be determined. The 

greatest effect on the cutting force and moment during the end milling of aluminum 

6082-T6 with solid carbide end mill has the depth of cut, followed by the feed rate and 

the spindle speed. By increasing the depth of cut and the feed rate, the cutting force and 

the moment increase, while increasing the spindle speed causes decrease of the cutting 

force and moment, Fig. 4 (a), (b). The effect on surface roughness during the end milling 

of aluminum 6082-T6 has the feed rate. By increasing the feed rate, surface roughness 

increases, while increasing the spindle speed and depth of cut causes decrease of surface 

roughness, Fig. 4 (c). 



 Influence of Cutting Parameters on Force, Moment and Surface Roughness in End Milling 163 
 

 

(a) 

 

(b) 

 
(c) 

Fig. 4 Influence of n, Vf and ap on: a) cutting force, b) moment and c) surface roughness 

To simulate the process in terms of the cutting force, a mathematical model was developed 

using the multiple regression method. The mathematical model is given in Eq. (1): 

 
ppfpfc

naaVaVnF 94.609.1029.4316.3636.1481.103 −+++−=  (1) 

The coefficient of determination is R2=99.85%, while the adjusted coefficient of 

determination is R2(adj)=99.26%.  

The mathematical model of the moment is given in Eq. (2): 

pfpfpfpf
anVaVnanVaVnM 0763.01888.01187.01137.04462.03812.01763.09188.0 −++−−++−=  (2) 

The coefficient of determination for the moment is R2=99.92%, while the adjusted 

coefficient of determination is R2(adj)=99.58%. 



164 J. STANOJKOVIĆ, M. RADOVANOVIĆ 

The mathematical model of surface roughness is given by Eq. (3): 

pfpfpfpf
anVaVnanVaVnRa 06425.00315.02835.02165.027425.002125.148575.00055.3 −++−−+−=  (3) 

The coefficient of determination of surface roughness is R2=99.99%, while the 

adjusted coefficient of determination is R2(adj)=99.97%. 

Based on the 3D surface plots of the cutting force, moment and surface roughness one 

can study the relations among the influencing factors during the end milling of aluminum 

alloy 6082-T6, Fig. 5. 

 

(a) 

 

(b) 

 

(c) 

Fig. 5 3D surface plots of a) cutting force, b) moment and c) surface roughness 

4. CONCLUSIONS 

Investigating the cutting force, moment and surface roughness is important for the 

process of milling. The cutting force and moment are the basic criteria for evaluation of 

machinability, while surface roughness is the basic criteria for the quality of parts. The 

knowledge of these performances facilitates the effective planning of the machining process. 

The measurement of the cutting force, moment and surface roughness was carried out 

for different values of spindle speed (320.405 and 560 rev/min), feed rate (62, 93 and 

175 mm/min) and depth of cut (0.4, 0.7 and 1.2 mm) in the laboratory conditions on a 

universal milling machine during the milling of aluminum alloy 6082-T6 with solid 

carbide end mill, manufactured by Seco, without cooling. The cutting force and moment 



 Influence of Cutting Parameters on Force, Moment and Surface Roughness in End Milling 165 
 

were measured using a Kistler piezoelectric dynamometer, while surface roughness was 

measured on a Mahr profilometer. 

Based on the experimental results of the cutting force, moment and surface roughness, 

an analysis was performed in the Minitab 17 software package. In the end milling of 

aluminum 6082-T6, the greatest impact on the cutting force and moment is achieved by 

the depth of cut, followed by the feed rate and the spindle speed. By increasing the 

cutting depth and the feed rate the main cutting force and moment grow as well, while 

increasing the spindle speed reduces them. On the other hand, the feed rate has the 

greatest influence on surface roughness. By increasing the feed rate, surface roughness 

increases as well, while increasing the speed and depth of cut causes decrease of surface 

roughness, i.e. a better quality of processing is achieved. 

Acknowledgements: The paper is a part of the research done within the project TR35034. The 

authors would like to thank to the Ministry of Education and Science, Republic of Serbia 

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