Surface Roughness Measurements Research Articles

Effects of various laser applications on surface roughness and bond strength to veneering composites of polyether ether ketone (PEEK) and polyether ketone ketone (PEKK) materials.

The aim of this study was to investigate the bond strength between PEEK/PEKK and composite resins after various laser treatments and to compare the effectiveness of lasers on these polymers. 130 disc-shaped PEEK and PEKK blocks were obtained (10mm diameter-4mm height). One sample from each group (10 in total) was selected for scanning electron microscopy (SEM) analysis. The samples were randomly divided into 5 different surface treatment groups for each material (PEEK and PEKK): Er: YAG laser, Nd: YAG laser, diode laser, femtosecond laser and control (no surface treatment) (n = 12). Baseline and post-treatment surface roughness measurements were performed using a profilometer. The composite resin was bonded and SBS was measured. Comparisons among the groups were conducted via Kruskal-Wallis, one-way ANOVA; Tukey and Dunn tests were used as a post hoc test (p ≤ 0.05). All lasers significantly increased the roughness values of the PEEK and PEKK samples. In terms of shear bond strength; the Er: YAG and femtosecond laser groups had the highest values and the Nd: YAG, diode and control groups had the lowest values of the PEEK samples (p ≤ 0.05). The control group had the highest bond strength values and the femtosecond group had the lowest values for PEKK samples (p ≤ 0.05). All laser treatments increased the surface roughness of the PEEK and PEKK. Lasers increased the bond strength of PEEK to the veneering composite resin and decreased the bond strength values of PEKK. This shows that lasers behave differently in PEEK and PEKK materials.

Effects of surface roughness on the drag coefficient of finite-span cylinders freely rolling on an inclined plane

We present an experimental investigation aimed at understanding the effects of surface roughness on the time-mean drag coefficient ( $\bar {C}_{D}$ ) of finite-span cylinders ( $\text {span/diameter} = \text {aspect ratio}$ , $0.51 \le AR \le 6.02$ ) freely rolling without slip on an inclined plane. While lubrication theory predicts an infinite drag force for ideally smooth cylinders in contact with a smooth surface, experiments yield finite drag coefficients. We propose that surface roughness introduces an effective gap ( $G_{eff}$ ) resulting in a finite drag force while allowing physical contact between the cylinder and the plane. This study combines measurements of surface roughness for both the cylinder and the plane panel to determine a total relative roughness ( $\xi$ ) that can effectively describe $G_{eff}$ at the point of contact. It is observed that the measured $\bar {C}_{D}$ increases as $\xi$ decreases, aligning with predictions of lubrication theory. Furthermore, the measured $\bar {C}_{D}$ approximately matches combined analytical and numerical predictions for a smooth cylinder and plane when the imposed gap is approximately equal to the mean peak roughness ( $R_p$ ) for rough cylinders, and one standard deviation peak roughness ( $R_{p, 1\sigma }$ ) for relatively smooth cylinders. As the time-mean Reynolds number ( $\overline {Re}$ ) increases, the influence of surface roughness on $\bar {C}_{D}$ decreases, indicating that wake drag becomes dominant at higher $\overline {Re}$ . The cylinder aspect ratio ( $AR$ ) is found to have only a minor effect on $\bar {C}_{D}$ . Flow visualisations are also conducted to identify critical flow transitions and these are compared with visualisations previously obtained numerically. Variations in $\xi$ have little effect on the cylinder wake. Instead, $AR$ was observed to have a more pronounced effect on the flow structures observed. The Strouhal number ( $St$ ) associated with the cylinder wake shedding was observed to increase with $\overline {Re}$ , while demonstrating little dependence on $AR$ .

Optimizing dry milling of stir-cast and heat-treated AZ80 magnesium alloy using multiple criteria optimization technique: an experimental study.

The primary aspects of this research are to evaluate surface roughness, cutting force, and material removal rate and optimize it with dry milling process parameters for heat-treated and stir-cast AZ80 magnesium alloy. Multiple methodologies are utilized in the research, which includes the Integration of design of experiments-response surface methodology for experimental design with the technique for order of preference by similarity to ideal solution for multi-criteria optimization. In order to evaluate the effect of process parameters on the response, the experimental design manipulates the depth of cut, feed rate, and cutting speed in a systematic manner. An evaluation of the machined surface's quality is conducted via surface roughness measurements. Likewise, insights into the forces exerted during milling can be obtained through continuous monitoring of cutting forces. The calculation of material removal rate is predicated on weight reduction. The interaction between the depth of cut and feed rate has a significant impact on the critical-to-quality characteristics of the alloy, which has contribution percentage greater than 25%. This finding validates that despite the heat-treated alloy having a similar composition to the as-cast alloy (where the closeness coefficient is 0.9843), the optimal process parameters of the former are not applicable to the latter. Nevertheless, the technique used to prepare the specimen has no bearing on the material removal rate, which is a process parameter-specific effect.

A comparative study of polishing systems on optical properties and surface roughness of additively manufactured and conventional resin based composites

This study aimed to compare polishing systems on color stability, surface roughness, and gloss of additively manufactured permanent and conventional resin composites. Totally 250 disc specimens (6 mm*2 mm) were prepared from resin-based materials [G-ænial Posterior (GP), Clearfil Majesty Esthetic (CME), SonicFill-2 (SF), Tescera (Tes), and Crowntec (CT)]. Following baseline color (ΔE00), gloss (GU), and surface roughness (Ra) measurements, the specimens were randomly divided into 5 groups (n = 10/group) according to polishing systems: Control (mylar strips); OneGloss; OneGloss + Platina Hi-Gloss; OptiDisc; and OptiDisc + Platina Hi-Gloss. Specimens were immersed in coffee for 144 h following polishing. ΔE00, GU, and Ra measurements were repeated. Atomic force microscopy images were taken in all groups. Spearman’s rho correlation coefficient, Robust ANOVA, and Bonferroni correction were used for statistical analysis. Significance level was taken as p < 0.050. Significant differences in ΔE00 values were found among resin-based materials, polishing systems, and their interactions (p < 0.001,p < 0.01, and p = 0.001). Regardless of polishing system, the lowest ΔE00 values were observed in CT, while lowest gloss (GU) values were found in Tes. The lowest surface roughness (Ra) values were detected at OptiDisc group (p < 0.001). A single type of polishing system may not be sufficient to achieve optimal results in resin-based materials.

Effect of Material on Lathe Rotation at HSS (High Speed Steel) M42 Tool Cutting Tool Wear Level

In an era where science and technology are rapidly developing, in the era of globalization it opens a wide door for every individual to embrace change. Human resources, being the pulse that pumps industrial life, must be proficient in mastering science and technology, being able to apply it in every step of the industry, and steel has become an important milestone in various sectors, from building construction to machine components. However, behind the glitter of this civilization, technical processes such as turning the HSS M42 chisel face its own challenges. At certain rpm cycles, the tool experiences an erratic level of wear, as evidenced by the difference between the initial and final weights as well as the difference in the initial and final lengths. In the HSS M42 tool turning attempt, the HSS M42 1200 type tool with a size of 3/8x3/8x4" and a rotation speed of 700, 900, and 1200 rpm, with a cutting depth of 1 mm and a feed rate of 0.09, almost encountered a weakness. Tools that wear out quickly, especially at 900 rpm, make turning results less satisfactory. However, there was a light at the end of the hallway. In the same process, the use of HSS tools with HSS M42 1200 type, dimensions of 3/8x3/8x4", was able to answer the challenge with more promising success. At 900 rpm rotation, the wear that occurs is more controlled, resulting in a workpiece with a satisfactory level of fineness, reaching N6 in the measurement of surface roughness. As if to be a symbol of struggle, HSS chisels are able to cut finer traces in the ocean of HSS M42 chisels

Evaluation of optical and mechanical properties of crown materials produced by 3D printing.

The various advantages of crown materials produced using three-dimensional (3D) printers have increased their use in restorative and prosthetic dentistry in recent years. Accordingly, their optical and mechanical properties have become more important. To evaluate the mechanical, surface and optical properties of crown materials produced with 3D printing and computer-aided design (CAD)/computer-aided manufacturing (CAM), which has recently been used frequently in the clinic. The 3-point bending test was used to evaluate the mechanical properties of 2 different crown materials produced with 3D printing (Permanent Crown and VarseoSmile Crown Plus) and a crown material produced using CAD/CAM (Vita Enamic). After the initial color and surface roughness measurements were made, the specimens were immersed in 4 different solutions. The most translucent material was VarseoSmile Crown Plus (p < 0.05). In all specimens, coffee caused the most discoloration (p < 0.05). The effects of the solutions on the roughness were mostly observed in Permanent Crown specimens (p < 0.05). Vita Enamic showed the highest statistically significant values in terms of flexural strength (p < 0.05). The stereolithographic technique among the materials produced by 3D printing can be recommended for use in restorations due to its higher flexural strength.

Functional properties of expanded austenite generated on AISI 316L by plasma nitrocarburizing using different active screen materials

Abstract This study investigates the functional properties of the expanded austenite layers generated on AISI 316L austenitic stainless steel resulting from active screen plasma nitrocarburizing using different active screen materials, i.e. steel or solid carbon. Treatments were conducted at 460 °C for 5 hours in a nitrogen-hydrogen feed gas, whereas for the treatments using a steel active screen, methane was added as carbon precursor. Additionally, the bias plasma conditions applied at the samples were varied between 0 kW and 1.25 kW. Samples were characterized by complementary microstructural and compositional investigations, surface roughness and hardness measurements, pin-on-disk tribological tests as well as potentiodynamic polarization tests in H2SO4 and NaCl electrolytes. The functional properties of the case are discussed based on the contents of nitrogen and carbon in the expanded austenite and on their effective diffusion depths. The results show that the usage of a carbon screen generally produces surfaces with uniform layer thickness, high hardness, improved wear resistance and a delayed tendency to pitting corrosion independent of the bias condition applied to the samples. When applying both screen materials at non-biased condition, the general corrosion resistance is slightly reduced under the conditions used, however, the layers generated using the carbon screen have a wear rate that is 3 times lower. It can be concluded that the carbon screen represents a robust treatment variant for austenitic stainless steels to produce sufficiently thick and wear-resistant surface layers in a short treatment duration, which still have the potential to maintain the corrosion resistance in different environments.

Corrosion-Resistant Polymer Composite Tubes with Enhanced Thermal Conductivity for Heat Exchangers

The heat transfer surfaces of heat exchangers are usually made of metals which may suffer from severe corrosion. When corrosive fluids are present, highly corrosion-resistant metals, graphite or ceramics are used, resulting in high costs. This study presents measured data on the thermophysical and mechanical properties of recently developed corrosion-resistant polymer composite tubes for use in heat exchangers. Extruded polymer composite tubes based on polypropylene or polyphenylene sulfide filled with graphite flakes were investigated. The anisotropic thermal conductivities of the polymer composite tubes were measured at various temperatures. The through-wall thermal conductivity of the tubes made of polypropylene filled with 50 vol.% graphite is increased by a factor of 30 compared to pure polypropylene, resulting in a thermal conductivity of 6.5 W/(m K) at 25 °C. The tubes composed of polyphenylene sulfide filled with 50 vol.% graphite have a through-wall thermal conductivity of 4.5 W/(m K) at 25 °C. The mechanical properties of the polymer composites were measured using tensile and flexural tests at different temperatures. The composite materials are more rigid and keep their mechanical properties up to a higher temperature level compared to the unfilled polymers. Surface roughness measurements show the very smooth and sealed surface of the composite tubes. The results contribute to establishing the viability of using polymer composites for heat exchanger applications with corrosive fluids.

Effect of manufacturing new U-shaped electrode on die sinking EDM process performance

Traditional electrical discharge machining (EDM) electrodes have several limitations such as long machining time, low material removal rate MRR, hazard emissions and high energy consumption. To overcome these limitations, new electrodes (plane and frame U-shaped) were manufactured considering the electrode manufacturing classifications, such as electrode flushing mechanism, electrode cross-sectional area and electrode bottom machining area. Experiments were performed on a die-sinking EDM machine using copper electrodes and aluminum alloy workpieces. The results were compared with those obtained using the conventional electrode. The newly manufactured electrodes significantly improved the EDM process performance, reducing the machining time by more than 50%, which implies a higher MRR. The reduced machining time also led to lower costs, emissions and energy consumption for efficient EDM processes. Additionally, surface roughness measurements were performed to compare the surface quality of the machined areas using different pulse-code generator systems and electrodes. The results showed an improvement in the machined surface quality when using the new electrodes in comparison with the conventional electrode when using a roughing pulse code generator system.

Surface roughness metrology with a raster scanning single photon LiDAR

We explore a novel, to the best of our knowledge, approach to surface roughness metrology utilizing a single pixel, raster scanning single photon counting LiDAR system. It uses a collimated laser beam in picosecond pulses to probe a surface, capturing the changes of back-scattered photons from different points on the surface into a single mode fiber, and counting them using a single photon detector. These back-scattered photons carry speckle noise produced by the rough surface, and the variation in photon counts over different illumination points across the surface becomes a good measure of its roughness. By analyzing the variation frequency as the LiDAR scans over the surface using machine learning techniques, we demonstrate general measurements of surface roughness from 1.21 (1.27±4.51) to 102.01 (87.97±10.55) microns.

Indirect measurement of bridge surface roughness using vibration responses of a two-axle moving vehicle based on physics-constrained generative adversarial network

This study addresses the challenge of indirectly measuring bridge surface roughness through the vibration responses of a moving vehicle, which is crucial for pavement maintenance and bridge safety assessment. A physics-constrained generative adversarial network (PC-GAN) was proposed for the probabilistic estimation of surface roughness. The method consists of two steps: initially, a GAN informed by physics-based knowledge extracts combined information of bridge vibration deflection and surface roughness from vehicle accelerations. Subsequently, a feed-forward network isolates the bridge surface roughness from the combined data. Numerical examples validate the PC-GAN method, demonstrating sustained high accuracy under challenging conditions, including ISO 8608 level C road roughness, vehicle speeds up to 8 m s-1, 10 % deviation in vehicle parameters, 10 % environmental noise, and 10 % vehicle damping ratio. Laboratory tests further confirmed the method's efficacy, with the successful detection of artificial barriers on the bridge surface and a mean relative error of 3.33 % in height estimation. The PC-GAN method is demonstrated to be a robust tool for estimating bridge surface roughness under various numerical and laboratory conditions. These findings provide valuable insights for the rapid inspection of bridge pavement conditions using vibration responses from moving test vehicles.

Characterization of surface integrity of 7075-T6 aluminum alloy subjected to microbiologically induced corrosion during high-speed machining

Microbiologically Influenced Corrosion (MIC) is one of the primary causes of corrosion damage and equipment failure in industrial environments. This paper aims to investigate the impact of microbiologically influenced corrosion on the surface integrity of 7075-T6 aluminum alloy. Through experiments involving cryogenic treatment and machining, the study systematically compares the effects of different microbiologically influenced corrosion environments on 7075-T6 aluminum alloy. Techniques such as X-ray Diffraction (XRD), surface roughness measurement, Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and work hardening were used to elucidate the influence of natural seawater (Planktonic microorganisms, PM) and marine sediment (Benthic microorganisms, BM) corrosion on the surface integrity of 7075-T6 aluminum alloy.The results indicate that, compared to PM corrosion, BM corrosion results in a smaller surface roughness of 7075-T6 aluminum alloy. Specifically, the BM-10d specimen exhibits the smallest roughness at 0.353 μm. XRD and EDS analyses show that the corrosion products after microbiological corrosion are primarily a mixture of Al2O3, AlO(OH), and Al(OH)3. The peak intensity of AlO(OH) in the (200) crystal plane of the BM-5d corrosion product is notably higher than that of the 7075-T6 aluminum alloy under other conditions. In the PM environment, the corrosion products fully cover the entire surface of the workpiece and are accompanied by significant cracking. In contrast, in the BM environment, the corrosion products mainly exhibit a granular structure, are scattered across the workpiece surface, and the exposed substrate can be observed.The microhardness of the aluminum alloy after microbiological corrosion shows a trend of increasing initially, then decreasing, and finally stabilizing. The maximum depth of the hardened layer for PM-10d is 120 μm, with a maximum hardness of 178.74 HV. Compared to PM corrosion, BM corrosion results in a significantly greater hardened layer depth for 7075-T6 aluminum alloy, with the BM-10d hardened layer depth reaching approximately 140 μm and the peak hardness at 185.36 HV. Additionally, in the BM environment, the precipitates are fewer compared to those in the PM environment and exhibit a non-continuous, non-grain-boundary precipitation band.

THE INFLUENCE OF THE CUTTING PARAMETERS ON THE SURFACE ROUGHNESS AND VIBRATION SIGNAL IN THE TURNING PROCESS

The performance of the final part of the turning process, a topic of practical importance, heavily depends on the cutting parameters. Surface quality, a crucial product attribute in manufacturing, often tops consumer demands during machining due to its significant influence on product functionality. This paper assesses the correlation between the detected vibration signal, statistical parameters (Crest, Kurtosis and I-kaz3D coefficient) and surface roughness and provides valuable insights for practical applications. When the tool experiences vibrations during material removal, these oscillations leave a ripple effect on the surface of the workpiece. We aim to determine the impact of cutting parameters on surface roughness while turning 42CrMo4 steel using a carbide tool insert. Cutting parameters, such as spindle speed, feed, and depth of cut, were used. Signal processing is carried out using different techniques to identify the effect of the cutting parameters on vibration signals. Finally, we delve into the interaction effects between the cutting parameters, vibration signals and surface roughness, offering a comprehensive understanding of real-world manufacturing scenarios. Higher I-kaz3D coefficients correspond to higher surface roughness values. The I-kaz3D coefficient decreases as the surface roughness measurements decrease, indicating that the I-kaz3D technique can accurately indicate an increase or decrease in surface roughness. On the other hand, the cutting force Fc was the component most strongly correlated with surface roughness (Ra), yielding the best results across all indices (adjusted R²adj = 95.1%, er=.8 ± 2.3%).

Effect of laser irradiation during in-office tooth bleaching on surface properties of resin-based restorative materials.

This study evaluated the changes in surface properties of three resin-based restorative materials after two laser-assisted, in-office tooth bleaching protocols using erbium, chromium: yttrium-scandium-gallium-garnet (Er,Cr:YSGG) or diode (980nm) lasers. A nanohybrid composite (Enamel Plus HRi), a Bis-GMA-free composite (Enamel Plus HRi Bio Function), and a resin-matrix CAD-CAM ceramic (Shofu Block HC) were tested. Forty specimens for each material were prepared and divided into four groups (n=10/group). The control specimens did not undergo any bleaching treatment, whereas group 2 received bleaching with 40% hydrogen peroxide (H2O2), while groups 3 and 4 underwent the same bleaching procedure with the use of diode (980nm) or Er,Cr:YSGG lasers, respectively. Surface microhardness and roughness measurements were conducted using a Vickers tester and an optical profilometer. Microhardness was lower in bleached specimens, with the nanohybrid composite exhibiting the largest difference from the no bleaching group. For the Bis-GMA-free composite the microhardness difference between no bleaching and laser-assisted bleaching were smaller than seen for the conventional bleaching technique. Surface roughness was higher in bleached specimens, with nanohybrid composite showing the largest differences from the control specimens. The examined laser-assisted tooth bleaching protocols were found not to impact surface microhardness and roughness of the tested resin-based specimens and they are deemed suitable for clinical use.

Surface Roughness Measurement of Hybrid Ceramic Materials after Immersion in Mouth Rinse and Repolishing

Surface Roughness Measurement of Hybrid Ceramic Materials after Immersion in Mouth Rinse and Repolishing

Titaniumdioxide Reinforced Glass-Ionomers with Different Surface Roughness Measurement Methods

Titaniumdioxide Reinforced Glass-Ionomers with Different Surface Roughness Measurement Methods

Characterization of Ni-Cu multilayers deposition on low carbon steel substrate using electroplating technique

Abstract Low carbon steel is widely used in oil and gas applications. In this research, multilayers of Nickel (Ni) and Copper (Cu) were deposited on a low carbon steel substrate using the electroplating process (ELP). Initially, a layer of Ni was coated, followed by a layer of Cu. ELP was implemented using water bath containing (300 g/l) of NiSO4.6H2O, (30 g/l) of (NiCl2.6H2O), (40 g/l) of H3BO3 and (30 g/l) of (NaCN), (30 g/l) of (CuCN), (10 g/l) of (NaOH.6H2O). First bath parameters were temperature is (59 - 60 °C), current density in the range of (3-5 A/dcm2), voltage was holed at (8 V) for Ni, and temperature was between (50-51 °C), current density in the range of (1-2 A/dcm2), voltage was holed at (4 V), while the plating time (10 minutes) for both Ni and Cu. The results refer to Ni, Cu, and Ni &amp; Cu ELP thicknesses 3, 4.77 and 6.75 μm respectively. Metallurgical tests were achieve including the micro hardness of ELP, Vickers micro hardness results showed improvement in hardness values compared, with steel substrate, and in the presence of Ni, Cu, Ni+Cu layers, 322, 581, 479, and 562 Hv respectively. The roughness was measured using surface roughness measurement device. The average surface roughness (Ra) depicted satisfying values as a result of Ni layer coating, which gave uniform surface distribution with Ra 0.363 μm. X-ray diffraction (XRD) test examinations serve as strong evidence for the presence of Ni and Cu in the internal and external finish layers, respectively. Corrosion examinations were carried out in seawater solution (3.5 g NaCl) the corrosion behavior tends to be more resistance, with layers of Ni, and Cu in sea water environment, which is considered an important criterion to increase the part life.

Evolution of Lubrication Characteristics of Double-Nut Ball Screws Based on an Efficient Surface Roughness Modeling Method

Abstract Accurate prediction of lubrication characteristics, specifically film thickness and pressure distribution, is pivotal for ensuring optimal performance in ball screws. Despite its significance, there is a notable dearth of studies investigating the evolution of lubrication characteristics resulting from the changing surface roughness over prolonged operation of ball screws. Furthermore, obtaining the surface roughness of ball screws poses a challenge due to the limited loading capacity of measurement instruments. Traditional methods involving cutting the screw for surface roughness measurement are impractical for continuous monitoring during extended operation. To address this issue, the present study introduces an efficient approach to model the surface roughness of the raceway in double-nut ball screws. A profilometer is employed to measure profile roughness along two directions (parallel and perpendicular to the rolling direction) without the need to cut the screw raceway. The 2D power spectral densities and height probability densities of profile roughness are calculated to model the surface roughness, and the synthesized data are utilized to solve the Reynolds equation. The simulation method is validated through friction torque tests, demonstrating a calculation accuracy exceeding 92%. The study further explores the evolution of film thickness and pressure distribution in double-nut ball screws during running-in and steady wear stages, revealing severe asperity contact in the two nuts. Additionally, variations in load ratio, friction coefficient, and film thickness ratio (λ) are investigated. Considering the load ratio and λ of the slave nut, it can be inferred that boundary lubrication persists in the two nuts throughout the operation.

Surface roughness measurement in the notch area for estimating dynamic component load bearing capacity

The surface of a part can have an essential influence on its dynamic load bearing capacity as grooves and scratches act as more or less significant imperfections or additional micro-notches, depending on the interpretation. In order to accurately predict the fatigue strength, detailed knowledge of the surface structure in critical areas is essential but cannot always be established due to geometric constraints. To overcome these restrictions, a method utilizing impressions and a laser scanning microscope to take surface topography measurements in critical notch areas is used in this work. It enables precise and reproducible measurements to be taken. The method is used to conduct surface roughness measurements on fatigue strength specimens made of four different materials. Several roughness influence factors are calculated based on the results and their influence on the result of a recalculation using a fatigue strength assessment is shown as example. The calculated fatigue limit is compared against experimental results. The comparison shows significant scatter in prediction accuracy and no optimal surface influence factor can be recommended so far. It has to be noted that only a small sample of specimens, which were not designed for researching surface roughness influence in particular, were available for this work. The effects of roughness in the notch may not be completely captured by the available roughness influence factors. Furthermore, issues arise in the correct implementation of stress concentration factor based roughness influence factors. Further research is required to provide a more comprehensive understanding of the effects of surface roughness on the fatigue limit.

Design and Technological Aspects of Integrating Multi-Blade Machining and Surface Hardening on a Single Machine Base

Modern mechanical engineering faces high competition in global markets, which requires manufacturers of process equipment to significantly reduce production costs while ensuring high product quality and maximum productivity. Metalworking occupies a significant part of industrial production and consumes a significant share of the world’s energy and natural resources. Improving the technology of manufacturing parts with an emphasis on more efficient use of metalworking machines is necessary to maintain the competitiveness of the domestic machine tool industry. Hybrid metalworking systems based on the principles of multi-purpose integration eliminate the disadvantages of monotechnologies and increase efficiency by reducing time losses and intermediate operations. The purpose of this work is to develop and implement a hybrid machine tool system and an appropriate combined technology for manufacturing machine parts. Theory and methods. Studies of the possible structural composition and layout of hybrid equipment at integration of mechanical and surface-thermal processes were carried out, taking into account the basic provisions of structural synthesis and componentization of metalworking systems. Theoretical studies were carried out using the basic provisions of system analysis, geometric theory of surface formation, design of metalworking machines, methods of finite elements, and mathematical and computer modeling. The mathematical modeling of thermal fields and structural-phase transformations during HEH HFC was carried out in ANSYS (version 19.1) and SYSWELD (version 2010) software packages using numerical methods of solving differential equations of unsteady heat conduction (Fourier equation), carbon diffusion (2nd Fick’s law) and elastic–plastic behavior of the material. The verification of the modeling results was carried out using in situ experiments employing the following: optical and scanning microscopy; and mechanical and X-ray methods of residual stress determination. Formtracer SV-C4500 profilograph profilometer was used in the study for simultaneous measurement of shape deviations and surface roughness. Surface topography was assessed using a Walter UHL VMM 150 V instrumental microscope. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD. Results and discussion. The original methodology of structural and kinematic analysis for pre-design studies of hybrid metalworking equipment is presented. Methodological recommendations for the modernization of multi-purpose metal-cutting machine tool are developed, the implementation of which will make it possible to implement high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and provide the formation of knowledge-intensive technological equipment with extended functionality. The innovative moment of this work is the development of hybrid metalworking equipment with numerical control and writing a unique postprocessor to it, which allows to realize all functional possibilities of this machine system and the technology of combined processing as a whole. Special tooling and tools providing all the necessary requirements for the process of surface hardening of HEH HFC were designed and manufactured. The conducted complex of works and approbation of the technology of integrated processing in real conditions in comparison with traditional methods of construction of technological process of parts manufacturing allowed to obtain the following results: increase in the productivity of processing by 1.9 times; exclusion of possibility of scrap occurrence at finishing grinding; reduction in auxiliary and preparatory-tasking time; and reduction in inter-operational parts backlogs.