Study on the surface integrity of AISI 4140 steel after turning

ABSTRACT Machine components are usually subjected to cyclic loads, which may lead to failure, even when the component is subjected to elastic deformations only. Manufacturing processes are capable of affecting roughness and inducing residual stresses of distinct levels and depths, being able to affect the component performance and lifespan. This work investigates the influence of turning parameters (cutting speed, feed and depth of cut) on surface roughness, residual stress and fatigue life of hardened AISI 4140 steel (40 HRC). Feed is the most influential parameter affecting surface roughness. It was noticed that the cutting parameters did affect the residual stress profile, i.e., tensile residual stresses of higher intensity were induced when higher cutting speeds were employed and reaching deeper layers when higher feed and lower depth of cut values were used. The fatigue life was evaluated under rotating bending tests, which indicated a combined influence of feed and depth of cut. At lower feeds, the increase of depth of cut resulted in longer lives, however, an opposite behavior was noted at higher feeds. Longer fatigue lives were observed after turning at higher cutting speeds and depths of cut combined with lower feeds.