Influence of Previous Turning on the Surface Integrity Stability of Diamond-Burnished Medium-Carbon Steel

There is a lack of information in the literature on the influence of technological heredity on surface integrity characteristics after diamond burnishing (DB). The present study fills this gap. Here, we present the effects of DB on the roughness parameters and surface microhardness of heat-treated C45 steel under conditions of changing initial roughness (Rainit) due to wear on the cutting insert in the previous turning. The aim was to quantitatively assess the ability of DB to maintain sustainable surface integrity characteristics. We found that the service life of the cutting insert up to complete wear or fracture when operating at an optimal feed rate and cutting velocity was 163 min, at which point the roughness changed unevenly from an average roughness (Ra) value of 0.38 to 1.31 μm and an average height of the profile microroughness (Rz) value of 2.21 to 6.13 μm. Under conditions of an artificially created Rainit (through different combinations of feed rate and cutting velocity) of 0.308 to 10.688 μm, DB provided Ra values in the range of 0.042 to 0.316 μm, with the surface microhardness varying from 461 to 568 HV. Stable Ra values were maintained from 0.042 μm to 0.089 μm, after which the Rainit increased to 3.379 μm. Under production conditions, where the previous turning was performed at an optimal feed rate of 0.05 mm/rev and a cutting velocity of 180 m/min, DB provided a stable Ra of ≤0.059 μm of a resulting mirror-like surface during the first 90 min of operation of a new (unused) cutting insert, after which the Ra values increased linearly from 0.059 to 0.133 μm in the 150th minute. After 30 min of operation, until the cutting insert was completely worn, the microhardness after DB varied from 676 to 795 HV, the high surface microhardness resulting from a complex process of surface thermo-mechanical strengthening (including strain and transformation hardening) in the previous turning due to wear on the cutting insert.