Abstract
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).
Highlights
Surface finishing processes as hard turning and grinding determine the surface integrity of machined parts, e.g., surface roughness, residual stresses, hardening and microstructure, which can be of decisive importance for its functional performance [1,2,3,4]
The concept of surface conditioning was elucidated by specific examples
Turning was presented multiple times, because the simple kinematic and the stationary tool engagement facilitates the investigation of innovative measurement variables and complex surface states
Summary
Cutting and abrasive processes modify the surface integrity of the workpiece by a combination of mechanical and thermal loads [7,8,9,10,11]. When turning AISI 4140 QT, different mechanisms such as work hardening, dynamic recrystallization and phase transformations may occur, depending on the tempering treatment, the process parameters and the tool wear [25]. It is not the existence of a white layer, but the microhardness which must be taken as the indicator for thermally transformed surface layers. Mechanical loads often lead to desired modifications such as nanocrystalline surface layers or compressive stresses This motivates the control of the thermomechanical loadings during cutting and abrasive machining. The presented examples show that those approaches are process- and workpiece material-specific and require an excellent knowledge of the physical mechanisms
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