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RESEARCH PRODUCT

Surface Integrity

subject

description

This chapter provides comprehensive knowledge regarding the state and properties of both surface and subsurface layers generated during machining processes, including different associated mechanical and thermal influences. Basic models of the superficial layer and factors effecting surface integrity are presented. Decomposition of surface topography into roughness, waviness and form along with appropriate filtering methods is outlined. The characterization of surface roughness based on 2D and 3D roughness parameters as well as motif, fractal and frequency characteristics are presented. In particular, all standardized areal surface parameters are specified, and practical examples are provided. Theoretical models of surface roughness generated in turning and milling operations are derived. The methods of surface roughness measurement are overviewed and the examples of measurement instruments (both contact based on the stylus and noncontact based on white light or laser interferometry) are provided. Mechanical properties of the subsurface layer, including strain hardening effect caused by plastic deformation and residual stresses induced by thermal and/or mechanical influences, are characterized and supported by practical case studies for different materials and machining processes. Some developing trends in numerical simulations and surface metrology are highlighted.