Surface integrity in metal machining - Part I: Fundamentals of surface characteristics and formation mechanisms

The surface integrity of machined metal components is critical to their in-service functionality, longevity and overall performance. Surface defects induced by machining operations vary from the nano macro scale, which cause microstructural, mechanical chemical effects. Hence, they require advanced evaluation post processing techniques. While varies significantly across range processes, this paper explores state-of-the-art research with an emphasis on governing mechanisms emerging approaches. In review, removal are grouped primary energy transfer mechanisms; mechanical, thermal based. Accordingly, resultant multi-scale phenomena associated analyzed. contribution these material workpiece surfaces/subsurface characteristics reviewed. Post-processing options for mitigation also discussed.