Optimal Pre-stressing the Surface of a Component by Superfinish Hard Turning for Maxium Fatigue Life

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This research project is to study and optimize the fatigue life for surfaces machined by superfinish hard turning. This will be accomplished by: (1) modeling the relationship between machining conditions, tool wear, surface integrity, and fatigue life of the superfinish hard turned surface, and (2) developing a methodology enabling optimal pre-stressing, through the optimal residual stress distribution generated by the best cutting conditions for fatigue life. The research results could lead to the replacement of grinding and superfinishing by single-point machining, benefiting the manufacturing industries that make bearings, gears, cams, shafts, tools, dies, etc. The research is fundamental and could lead to a significant improvement in the fatigue life of superfinish hard turned surfaces. A major strength of the project is its strong industry participation and support.