Roughness maps to determine the optimum process window parameters in face milling

•Roughness maps help identifying the optimum tool and cutting parameters.•Roughness was modelled as a split signal in two components: kinematic and stochastic.•The feed rate is the key cutting condition to modify roughness values.•The axial position of each teeth is crucial for roughness modelling in face milling.•Nose radius is an important parameter to control roughness values.