Title: Size-effects and surface integrity in machining and their influence on product sustainability

Authors: J.C. Outeiro, R. Kandibanda, J.C. Pina, O.W. Dillon Jr., I.S. Jawahir

Addresses: Faculty of Engineering, Portuguese Catholic University, Estrada Octavio Pato, Rio de Mouro, P-2635 631, Portugal. ' Caterpillar, Inc., WTS – Light Fabrications Design/Analysis, 27th St. and E Pershing Rd., Decatur, IL 62526, USA. ' Department of Physics, University of Coimbra, Rua Larga, Coimbra, P-3004 516, Portugal. ' Center for Manufacturing and Department of Mechanical Engineering, University of Kentucky, Lexington, KY 40506, USA. ' Center for Manufacturing and Department of Mechanical Engineering, University of Kentucky, Lexington, KY 40506, USA

Abstract: In machining, the specific cutting energy is known to exponentially increase as the uncut chip thickness decreases. This phenomenon has been known as |size-effect| is also observed by varying the cutting edge radius, especially when this radius is of the same order or greater than the uncut chip thickness. In such conditions, the quality of the machined surface can be significantly affected. In the work presented in this paper, the influence of the cutting edge radius on the quality of the machined surface was evaluated in terms of surface defects, residual stresses and micro-hardness. The paper presents an analysis of relevant experimental results and a modelling approach for controlled residual stresses in machining, all aimed at improving product sustainability, in terms of its resulting lifetime.

Keywords: machining; size effect; surface integrity; sustainable manufacturing; product sustainability; surface quality; surface defects; residual stresses; microhardness; modelling; product lifetime.

DOI: 10.1504/IJSM.2010.031623

International Journal of Sustainable Manufacturing, 2010 Vol.2 No.1, pp.112 - 126

Published online: 15 Feb 2010 *

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