Machining-Induced Surface Integrity Optimization of High-Carbon Alloy Steel for Enhanced Polymer–Metal Composite Interface Performance

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Ujwal Samadhan Gawai,

  • S. Irudayaraj,

  • Pramod Ram Wadate,

  • Sarang P. Joshi,

  1. PhD Research Scholar, Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R& D Institute of Science and Technology, Chennai, Tamil Nadu, India
  2. Professor, Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  3. Assistant Professor, Department of Mechanical Engineering, Ajeenkya D Y Patil School of Engineering, Pune, Maharashtra, India
  4. Professor, Department of Mechanical Engineering, JSPM’s Imperial college of engineering and research, Pune, Maharashtra, India

Abstract

The functional performance and structural reliability of polymer–metal hybrid composites are strongly influenced by the surface integrity of metallic substrates used for interfacial bonding and load transfer. In this context, machining-induced surface characteristics play a critical role in determining adhesion behavior, dimensional stability, and mechanical compatibility within composite architectures. The present study investigates the hard turning performance of a newly developed high-carbon alloy steel intended for composite-integrated structural applications, with the objective of enhancing surface integrity for improved polymer–metal interface performance. A hybrid multi-objective optimization framework integrating Taguchi design of experiments and Response Surface Methodology (RSM) was employed to systematically evaluate the influence of cutting speed, feed rate, and depth of cut on surface roughness and dimensional deviation. Statistical analyses, including signal-to-noise ratio evaluation and analysis of variance (ANOVA), were used to identify the most significant machining parameters affecting surface functionality. Second-order predictive models developed through RSM enabled the assessment of interaction effects among process variables and facilitated response surface analysis for performance prediction. A desirability-based optimization approach was subsequently applied to achieve simultaneous minimization of surface irregularities and dimensional inaccuracy under conflicting performance requirements. Experimental validation confirmed that the optimized machining conditions significantly improved surface finish and dimensional precision, thereby enhancing the suitability of the metallic substrate for integration into advanced polymer composite systems. The proposed methodology offers a scalable and application-oriented approach for surface integrity control of hardened alloys used in hybrid composite engineering environments.

Keywords: Dimensional Accuracy, Polymer–Metal Hybrid Composites, Composite-Compatible Machining, High-Carbon Alloy Steel, Multi-Objective Optimization.

How to cite this article:
Ujwal Samadhan Gawai, S. Irudayaraj, Pramod Ram Wadate, Sarang P. Joshi. Machining-Induced Surface Integrity Optimization of High-Carbon Alloy Steel for Enhanced Polymer–Metal Composite Interface Performance. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Ujwal Samadhan Gawai, S. Irudayaraj, Pramod Ram Wadate, Sarang P. Joshi. Machining-Induced Surface Integrity Optimization of High-Carbon Alloy Steel for Enhanced Polymer–Metal Composite Interface Performance. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239602


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Ahead of Print Subscription Original Research
Volume 14
02
Received 22/02/2026
Accepted 20/03/2026
Published 02/04/2026
Publication Time 39 Days
35

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