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The increasing demands of the desire for even more high quality products in terms of lower weight, compact design and higher resistance towards stresses require the optimization of existing products through further developments. By combining of two or more materials, for example high-strength steel and aluminium, to one compound hybrid solid components can be manufactured with locally adapted properties and functions. The cutting process as the final step in the process chain significantly influences the performance and lifetime of such components through the produced surface and subsurface properties. The choice of a suitable tool for setting defined subsurface and surface properties turns out to be very difficult and has not been investigated sufficiently for hybrid components so far. The tool should generate the highest possible compressive residual stresses in the component with good surface quality. Therefore, this paper investigates and discusses the influence of different inserts with varying cutting nose radii as well as substrate and coating materials on process forces, process temperatures and surface roughness.

Influence of Tool Properties on the Thermomechanical Load during Turning of Hybrid Components and the Resulting Surface Properties