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The surface integrity strongly affects the performance properties of parts. Therefore, it is of great importance to be able to measure and adjust the surface-layer properties during the manufacturing process. In particular, cutting operations are characterized by high mechanical loads and temperature gradients in the area of chip formation. To enable a targeted control of the surface-layer properties, a fundamental comprehension of the interrelationships between the thermomechanical impact and the thereby induced material modification is required. Hence, the subject of this study is to measure the thermomechanical changes during turning of the aluminium alloy EN AW-2017 and find correlations thereof to the surface integrity. In order to achieve a large variation of the thermal and mechanical loads, the feed  f  (0.04 mm to 0.2 mm) and the depth of cuta    p{a_{\mathrm{p}}}    (0.4 mm to 2 mm) are varied over a wide range. The cutting speedv    c{v_{\mathrm{c}}}    is kept constant (300 m/min). For the in-process measurement of the temperatures and contact conditions at the interface of the tool and the specimen, a tool-workpiece thermocouple is used. Additionally, the components of the resultant force are measured by a dynamometer. The characterization of the surface layer is performed by the measurement of the residual stresses using X-ray diffraction and supplemented by the determination of the geometrical properties of the machined surface using a stylus measurement instrument. The results show an increase in temperature and the components of the resultant force with the enlargement of the cross-section of the undeformed chip. Due to the temperature gradient, tensile residual stresses are introduced in the tangential direction of the surface layer. Compressive residual stresses occur only in the axial direction and can be correlated with the in-process measurement data by introducing the  C -value. Consequently, the calculation of the presence of compressive residual stresses allows for a targeted control of the surface-layer properties during machining.

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Metrological characterization of the thermomechanical influence of the cross-section of the undeformed chip on the surface properties in turning of the aluminum alloy EN AW-2017