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<p>This study investigates the impact of random rough surfaces on the micromachining mechanism of FeCoNiCrAl high-entropy alloy. Using finite element simulations and experiments, variations in cutting force, cutting temperature, chip morphology, machined surface quality, and residual stress under different surface roughness conditions were analyzed. The results reveal that increased surface roughness significantly affects cutting forces and temperature distribution. When the surface roughness deviation increases from 10&#xa0;μm to 20&#xa0;μm and the cutting depth rises from 150&#xa0;μm to 300&#xa0;μm, the fluctuations in cutting force and residual stress become more pronounced. When the surface roughness is 20&#xa0;μm, an increase in cutting depth from 150&#xa0;μm to 300&#xa0;μm results in an 80.4% increase in the average tangential force. At higher cutting speeds, chip curling and fracture also intensify. Rough surfaces increase friction, reducing the size of high-temperature regions. Regarding cutting temperature, while increased cutting depth and speed expand the high-temperature zone, irregular contact on rough surfaces diminishes thermal conduction efficiency. At a cutting depth of 200&#xa0;μm, the cutting temperature decreases by 4.4% as the surface condition transitions from a smooth surface to a surface roughness of 20&#xa0;μm. Experimental results also demonstrate that as cutting depth and surface roughness increase, the quality of machined surface morphology deteriorates significantly, showing more cracks and irregular textures. Residual stress analysis indicates that rougher surfaces lead to greater fluctuations in residual stress, especially at larger cutting depths and higher cutting speeds. When the cutting depth increases from 150&#xa0;μm to 300&#xa0;μm, the maximum residual compressive stress increases by 66.2% for a surface roughness of 10&#xa0;μm and by 104.3% for a surface roughness of 20&#xa0;μm.</p>

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Study on the Influence of Random Surfaces on the Micromachining Mechanism of FeCoNiCrAl High-Entropy Alloy

  • 期刊论文

  • 发表日期：

    2025年12月17日

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  • Ping Zhang,
  • Hanping Zhou,
  • Shuai Ge,
  • Tengfei Zhang

摘要

This study investigates the impact of random rough surfaces on the micromachining mechanism of FeCoNiCrAl high-entropy alloy. Using finite element simulations and experiments, variations in cutting force, cutting temperature, chip morphology, machined surface quality, and residual stress under different surface roughness conditions were analyzed. The results reveal that increased surface roughness significantly affects cutting forces and temperature distribution. When the surface roughness deviation increases from 10 μm to 20 μm and the cutting depth rises from 150 μm to 300 μm, the fluctuations in cutting force and residual stress become more pronounced. When the surface roughness is 20 μm, an increase in cutting depth from 150 μm to 300 μm results in an 80.4% increase in the average tangential force. At higher cutting speeds, chip curling and fracture also intensify. Rough surfaces increase friction, reducing the size of high-temperature regions. Regarding cutting temperature, while increased cutting depth and speed expand the high-temperature zone, irregular contact on rough surfaces diminishes thermal conduction efficiency. At a cutting depth of 200 μm, the cutting temperature decreases by 4.4% as the surface condition transitions from a smooth surface to a surface roughness of 20 μm. Experimental results also demonstrate that as cutting depth and surface roughness increase, the quality of machined surface morphology deteriorates significantly, showing more cracks and irregular textures. Residual stress analysis indicates that rougher surfaces lead to greater fluctuations in residual stress, especially at larger cutting depths and higher cutting speeds. When the cutting depth increases from 150 μm to 300 μm, the maximum residual compressive stress increases by 66.2% for a surface roughness of 10 μm and by 104.3% for a surface roughness of 20 μm.