Surface Integrity and Roughness of Characterization in Milling Processes
Abstract
Precision manufacturing in the aerospace, automotive and medical sectors relies on milling to put the finishing touches on high-performance components. Yet the very nature of the operation is a problem: the cutting tool’s edge engages with the workpiece in an aggressive fashion, prompting mechanical, thermal and chemical changes that can leave the finished hardware quite different from what was intended. In this paper we set out to examine the two sides of processed boundaries. On one hand there's surface topography in the form of roughness, lay and spatial patterns; on the other, subsurface metallurgical shifts like residual stress, plastic deformation and variations in microhardness. Through a combination of experimental diagnostics, physics-based characterization and analytical modeling, we show how such things as tool wear, geometry, feed per tooth and cutting speed will modulate the topography. We also make the case for linking macroscopic finish to mechanical properties-fatigue limit and wear among them-in order to provide a sound basis for optimizing both process and structural integrity at the same time.Abstract not available
Keywords
Surface Integrity, Surface Roughness, Milling Process, Machining Parameters