Manufacturing Surface Technology: Surface Integrity & Functional Performance

The manufacturing process unit event creates a pattern or texture on the surface that is a function of the tool shape and the machine relative motions. For example, the passage of a cutting tool leaves a path corresponding to the tool shape and the next event, one feed rate on, has a minimal influence on the surface generated by the previous event. On the other hand, in the lapping process, the unit events are cumulative. The passage of a lapping particle leaves a path, which the following grit modifies, crosses or even covers. Events occur on top of one another such that the total surface is the cumulative sum of a multitude of single events. Other examples of this are grinding or honing. Between these two extremes are manufacturing processes in which the events are multi-stage, where two or more individual events occur in a staged manner within the one process. End-milling is an example of this. The forward teeth remove metal and create a series of cusp shaped arcs. This is stage one, stage two then occurs when the back teeth cross over these arcs and modify (cut and/or burnish) the previous surface by creating arcs of an opposite hand. Other examples occur in hole manufacturing processes like twist drilling or gun drilling, where the drill lands or the pads modify the surface initially created by the outer corners of the cutting edges. Surfaces can also be generated by a combination of types...