Surface integrity in metal machining - Part I: Fundamentals of surface characteristics and formation mechanisms

Liao, Zhirong; Monaca, Andrea la; Murray, James W.; Speidel, Alistair; Ushmaev, Dmitrii; Clare, Adam T.; Axinte, Dragoş; M’Saoubi, Rachid

doi:10.1016/j.ijmachtools.2020.103687

Cited by 251 publications

(46 citation statements)

References 300 publications

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“…Cutting and abrasive processes modify the surface integrity of the workpiece by a combination of mechanical and thermal loads [7][8][9][10][11]. The combined load collective is influenced by the process parameters, e.g., a higher cutting velocity leads to increased process temperatures, while the process forces maintain or decrease due to thermal softening.…”

Section: Causes and Modification Of Surface Layer Statesmentioning

confidence: 99%

The Present State of Surface Conditioning in Cutting and Grinding

Stampfer

González

Gerstenmeyer

et al. 2021

JMMP

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All manufacturing processes have an impact on the surface layer state of a component, which in turn significantly determines the properties of parts in service. Although these effects should certainly be exploited, knowledge on the conditioning of the surfaces during the final cutting and abrasive process of metal components is still only extremely limited today. The key challenges in regard comprise the process-oriented acquisition of suitable measurement signals and their use in robust process control with regard to the surface layer conditions. By mastering these challenges, the present demands for sustainability in production on the one hand and the material requirements in terms of lightweight construction strength on the other hand can be successfully met. In this review article completely new surface conditioning approaches are presented, which originate from the Priority Program 2086 of the Deutsche Forschungsgemeinschaft (DFG).

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Section: Causes and Modification Of Surface Layer Statesmentioning

confidence: 99%

The Present State of Surface Conditioning in Cutting and Grinding

Stampfer

González

Gerstenmeyer

et al. 2021

JMMP

View full text Add to dashboard Cite

show abstract

“…The first is related to surface quality or surface topography and the second refers to characteristics of the machined substrate such as microstructure, mechanical properties and residual stresses (Davim, 2010). The most commonly used parameter for characterizing surface quality is the arithmetic average roughness, Ra, expressed in µm (Liao et al, 2021). Figure 10 shows most of the characteristics of the layers that form on the machined surface.…”

Section: Surface Integritymentioning

confidence: 99%

Experimental Milling Studies on Hardened Steels - A Review

Malea¹,

Niţu²,

Iordache³

et al. 2021

IJMMT

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Hardened steels have numerous applications in the construction of molds and dies due, in particular, to their outstanding thermo-mechanical characteristics, such as wear resistance and high stiffness, but especially dimensional stability at high temperatures. Machined surfaces are conditioned to have important tribological characteristics. Thus, a high quality of machined surfaces is achieved by milling processes with high cutting speeds. These types of processes even manage to replace grinding or electro-erosion machining processes with a solid electrode. The paper presents a review of experimental studies in recent years from industry and scientific research. Issues are outlined which justify the utility of machining hard metals by machining processes, with a focus on machining by milling processes. Starting from input parameters, such as technological parameters, blank material, cutting tool material and machining environment, their influence is analysed on output parameters, such as chip morphology, cutting tool wear and surface integrity.

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“…In most cases, to prevent early failure and fatigue of the parts, the smoothest surface finish is desirable [7]. After any thermos-mechanical manufacturing operation such as machining processes, different features of surface integrity are affected [8].…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Surface Integrity of Ti6Al4V by Broaching

2022

IJE

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T he performance of many parts in the airplane, aircraft engine and biomedical implants is highly related to their fatigue life, which is clearly depend on the condition of their surface integrity. T he geometry parameters of broaching tools have an important influence on the surface integrity after broaching T i6Al4V alloy. Therefore, this research studies the surface integrity of T i6Al4V by broaching. The surface integrity is studied at different geometric parameters such as rake angles (α, and α0), clearance angles (β, and β0), and radius of the cutting edge (r0) in two last teeth of the broaching tool that perform chipping. T he broached surface integrity is assessed in cases of surface roughness, microstructural, residual stresses, and micro hardness. These results show that the sample broached by tool number 1 (α = 18.4, β = 3.1, α0 = 45, β0 = 9, r0 = 0.02) had higher surface integrity because it was the smoothest surface and the thinnest deformed layer among the other samples. Since the main criterions in selection of the optimal tool are to create the smoothest surface and the least deformed layer depth in the broached sample, tool number 1(α = 18.4, β = 3.1, α0 = 45, β0 = 9, r0 = 0.02) is suggested as the optimal tool.

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Surface integrity in metal machining - Part I: Fundamentals of surface characteristics and formation mechanisms

Cited by 251 publications

References 300 publications

The Present State of Surface Conditioning in Cutting and Grinding

The Present State of Surface Conditioning in Cutting and Grinding

Experimental Milling Studies on Hardened Steels - A Review

Experimental Study on Surface Integrity of Ti6Al4V by Broaching

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