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Finish turning is one of the key operations governing the residual stress of functional surfaces. The residual stress state is determined by the cutting conditions and the selected cutting tool system (macro geometry, cutting edge preparation, tool substrate, multi-layer coating...). However, this initial configuration evolves over time due to tool wear. Therefore, it seems fundamental to reproduce the wear process of the tool in order to understand the evolution of thermo-mechanical loadings applied to the machined surface. This work presents a numerical methodology for predicting the wear-induced residual stress drift in longitudinal turning. The complete 3D cutting tool is discretized into elementary 2D sections. A finite element based procedure is developed to calculate, considering each local tool geometry, the local loads withstood by the machined material. The latter are merged to generate equivalent 3D thermomechanical loadings implemented in a second macroscopic model able to calculate the residual stress state under different wear levels. Experimental cutting tests with artificially worn tools have confirmed that good agreement can be achieved. [ABSTRACT FROM AUTHOR]

Drilling processes can significantly affect the surface integrity of metallic components. Thus, the control of the drilling process is of great interest for industry to ensure a satisfactory surface behavior. The understanding of such a process is complex because the hole is confined. Therefore, the physical phenomena are not easily observable during a drilling operation. The aim of this article is to present an experimental investigation on the effect of the drilling conditions for the machining of an austenitic stainless steel 316L. Three cases of lubrication are studied: internal coolant, external coolant and dry. The objective is to identify the mechanical and thermal contributions on surface integrity. In this study, the influence of the lubrication conditions is first characterized during the drilling operation (temperatures around the drilled surface, forces…). Then, the effect of lubrication on the surface integrity after drilling is clearly highlighted by analyzing the hole diameters, the drill deflections, the roughness, the residual stresses, the hardness and the microstructure.