In this work, the surface integrity smoothened with a ball end mill was investigated. Because surface integrity mainly affects the manual finishing process, RVAM (Remaining Volume After Machining) was introduced, and it gives the relation between machining process and finishing process. Runout and phase shift which adversely affect surface integrity were considered in the generation of surface topography. Cutting points in ball end milling were identified with positional vectors and a set of vectors which have the minimum height in unit area was selected for the generation of surface and RVAM RVAM variation according to runout and phase shift was calculated and experimentally verified in proposed HSM conditions for mold machining. From the simulations and the experiments, a desirable High Speed
Machining condition was suggested.
