Abstract
The effect of cutting speed and chip-tool contact length on the surface integrity of Inconel-718 nickel-base superalloy machined under both dry and lubricated orthogonal conditions is investigated. The surface and surface region of machined workpieces are examined using a wide variety of diagnos tic techniques. The results of the investigation show that a wide variety of geometrical surface features (damage) are generated. The results also show that a plastically deformed surface region is generated that contains variations in microstructure and residual stress. The quality of the machined surface improved significantly at high cutting speeds with tools having controlled contact lengths. The results of the investigation are interpreted in terms of the interaction between the chip and tool interface and that between the tool cutting edge region and the freshly machined workpiece surface and in terms of the variation in the tool forces with cutting conditions.
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