In this paper, the effects of edge preparation and cutting speed on surface integrity during machining of D2 tool steel (62 Rc) are examined. Tool wear, and surface finish are also measured and investigated. The x-ray diffraction technique is employed to measure the residual stresses distribution beneath the machined surface. The machined surface and subsurface are examined using optical and scanning electron microscopy. The thermally induced white layer is also investigated under different culling conditions. The results obtained show that the residual stresses induced are dependent on the combined effects of cutting conditions and the tool wear. Different types of surface and subsurface damage are also observed.

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