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During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool–chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear.

Surface quality of advanced superalloys after machining is one of the major issues in the aerospace industry because it directly affects service characteristics of the machined part. Tool life of cemented carbide inserts with the TiAlN coating during machining of direct aged DA 718 alloys under roughing and finishing conditions has been under study. The defect origin on the surface of the machined part was investigated. Metallographic observations of the DA 718 were made using optical metallography and SEM/EDS. To find out the origins of surface defect formation, the morphology of machined parts and cross sections of the machined surfaces have been investigated. Two major categories of defects were detected on the surface of the machined part: cracks and tears. The origin of the cracks on the machined surface is related to shearing of the primary complex TiC/NbC carbide revealed in a structure of DA 718 alloy. At the same time, Nb-rich regions of the primary complex carbide interact with the environment (oxygen from air) during machining with further formation of low strength oxide layer on the surface, forming tears.

Surface integrity of machined parts made from the advanced Ni-based superalloys is important for modern manufacturing in the aerospace industry. Metallographic observations of the ME 16 alloy microstructure were made using optical metallography and a high-resolution scanning electron microscope with energy dispersive x-ray spectrometer (HR SEM/EDS). Tool life of cemented carbide inserts with TiAlN coating during machining (finishing turning operation) of ME 16 superalloy has been studied and wear patterns of the cutting tools were identified. Surface integrity of the machined part after completion of the turning operation was investigated. The morphology of machined parts has been examined and cross-sections of the machined surfaces have been analyzed. The formation of white layer on the surface of the machined part was studied for varied machining conditions. It was found that a 2-4 lm thick white layer forms during turning of the ME 16 superalloy. This layer was investigated using EDS and XRD. The studies show that the white layer is an oxygen-containing layer with a high amount of aluminum, enriched by chromium and tungsten. Under specific cutting conditions, the structure of white layer transforms into a c-alumina. Formation of this thermal barrier ceramic white layer on the surface of the machined part negatively affects its surface integrity and cutting tool life.

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