Comparative Analysis of Surface Topography in Plunge and Face Milling: A Parametric Study into Skewness and Kurtosis

Optimizing milling procedures to enhance surface quality is crucial in modern manufacturing, where selecting appropriate strategies is paramount for achieving desired surface characteristics in precision-engineered components. This investigation provides a comparative experimental analysis of plunge milling (axial feed) versus face milling (radial feed), specifically evaluating their influence on achievable surface roughness when machining flat surfaces. Key machining parameters—cutting speed, feed per tooth, and depth of cut—were systematically varied for both techniques to quantify how their choice distinctly affects the final surface finish. Experimental results, supported by detailed statistical and graphical interpretation, demonstrated notable differences in surface quality between the two methods across various parameter settings. Consistently, face milling yielded superior surface quality compared to plunge milling under the investigated conditions and across the tested parameter range. The research clarifies the complex interplay and specific relationships between machining parameters and the resultant surface topography for both plunge and face milling. These findings offer practical guidance and valuable insights for optimizing parameter selection and choosing between milling strategies. This enables manufacturers to achieve specific surface roughness targets where surface integrity and finishing are critical quality criteria.