Identification of an optimal cutting edge microgeometry for Complementary Machining

The process strategy Complementary Machining combines machining and surface modification, resulting in optimal workpiece properties like fatigue strength. Right after machining the cutting tool is used reversely acting as a tool for a mechanical surface modification. The challenge of designing a cutting edge microgeometry that withstands the load spectrum and induces optimal surface layer states during Complementary Machining is solvable by modeling the resulting surface layer using FEM-simulation. Using the simulation-based analyses a deep process understanding is accomplished enabling further optimization of surface integrity (e.g. grain refinement) which is proven by measurements.