Analysis of surface roughness in HSM based on thermo-elastic-plastic theory

A mechanical model based on the molecular-mechanical theory of friction is presented to investigate the influence of the material behavior on surface roughness of the machined layer. According to thermo-elastic-plastic theory for large deformation, the flow stress increment is calculated for determining the cusp height (the remnant height on machined surface), which is induced by the strain hardening, the strain rate and the thermal loads in machining process. In addition, the relationships between the cusp height and the hardness of the material were discussed. The reasons for the observed differences in roughness between different material surfaces can be explained from the viewpoint of the molecular-mechanical theory of friction.