Complementary Machining – Machining Strategy for Surface Modification: A Review

All fabrication techniques utilized to manufacture metallic parts modify the surface integrity of the part. Complementary machining is a relatively recent machining strategy characterized by combining metal cutting and mechanical surface treatment. Typically, it implies that after conventional machining, the cutting insert is used reversely to modify the surface by local plastic deformation. To improve product performance, mechanical surface treatment is an additional phase in the manufacturing process chain that usually results in longer production times and higher costs. As a result, a variety of hybrid techniques have been created, such as complementary machining, which has the benefit of using conventional machine tools and their associated cutting tools. The study on complementary machining is reviewed in the article. The main focus is to assess the viability of complementary machining to modify surface integrity for enhanced properties by specifically establishing its effect on tool wear, surface roughness, microhardness, fatigue, microstructure, and residual stress state.