Surface Integrity

Abstract

Surface integrity comprises the study of the alterations induced during the manufacture of a component that might affect its properties and service performance. Therefore, additionally to geometric irregularities (surface texture and both dimensional and geometric deviations), the study on surface alterations (such as metallurgical alterations, cracks and residual stresses) induced by hard-part machining is of utmost importance, especially in the case of components subjected to dynamic loading. Consequently, this chapter is focused on the investigation of the influence of tool material and geometry and cutting parameters on the surface integrity of components subjected to hard-part machining and, when applicable, comparisons are drawn with grinding and non-conventional processes, especially electrical discharge machining (EDM). Geometric IrregularitiesOwing to the fact that in most cases hard-part machining is employed as an alternative to grinding, the requirements concerned with surface texture (microgeomet-__________________________________ A.M. Abrão

Cutting Speed and Feed Influence on Surface Microhardness of Dry-Turned UNS A97075-T6 Alloy

“…[4][5][6]. All these alterations (both material properties and geometry) are part of the surface integrity concept [7][8][9], which is one of the most valued aspects from the point of view of quality requirements, especially in structural elements for aircraft, where these requirements are very high due to functionality and reliability reasons [10].…”

Performance of ISO P and ISO S carbide tools in hard turning of AISI 4140 under dry and MQL conditions

“…According to distinct researchers, R a values tend to increase when the friction at the tool-workpiece interface leverages more than the growth of r e [7,8]; R a decreases when the effect of the r e increase overlaps with the friction's effect [27]; and R a remains almost constant when friction does not predominate over the increase of r e (steady state) [12].…”

“…feed-rate and tool nose radius), a special attention should be given to the deterioration of the tool nose edge in hard turning. In this case, faster tool-wear rates are observed, especially when the tool grade is not correctly selected, then resulting in poor surface finish [12].…”

“…The tool wear gradually increases until the cutting-edge breakage, which need to be avoided due to its harmful consequences. In finishing turning, the cutting edge must be replaced before the tool wear reaches values that threaten it in order to not affect the dimensional and surface quality of the workpiece [11][12][13]. A method to reduce the tool-wear rate is by adopting cutting fluids.…”

Study of Residual Stresses from Two Machining Protocols Using an Indentation Method

“…These stresses are caused by local plastic deformation generated by the interaction between the cutting tool and the component, and also, by the heat conducted from the primary deformation zone to the new surface [1,2]. In turn, both the local plastic deformation and heat flow depend on the mechanical properties of the machined component, as well as on the process parameters, geometry, design and condition of the cutting tool, and also, on the cooling conditions.…”