Experimental techniques for studying the effects of milling roller-burnishing parameters on surface integrity
01 Sep 2001-International Journal of Machine Tools & Manufacture (Pergamon)-Vol. 41, Iss: 12, pp 1705-1719
TL;DR: In this article, the effect of roller-burnishing on surface roughness, surface microhardness and residual stress of 6061-T6 aluminum alloy was investigated using a deflection-etching technique.
Abstract: Roller-burnishing is used in place of other traditional methods to finish 6061-T6 aluminum alloy. How to select the burnishing parameters to improve surface integrity (reduce surface roughness, increase surface microhardness and produce compressive residual stress) is especially crucial. This paper presents an investigation of the effect of roller-burnishing upon surface roughness, surface microhardness and residual stress of 6061-T6 aluminum alloy. The residual stress distribution in the surface region that was burnished is determined using a deflection-etching technique. Mathematical models correlating three process parameters: burnishing speed, burnishing depth of penetration and number of passes, are established. A Group Method of Data Handling Technique, GMDH, is used. It is shown that low burnishing speeds and high depths of penetration produce much smoother surfaces, whereas a combination of high speed with high depth leads to rougher surfaces because of chatter. The optimum number of passes that produces a good surface finish was found to be 3 or 4. The maximum value of compressive residual stress decreases with an increase in burnishing speed. The maximum compressive residual stress increases with an increase in burnishing depth of penetration and/or number of passes.
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TL;DR: In this article, the use of the ball burnishing process to improve the final quality of form tools (moulds and dies) is studied, which can be easily applied in the same machining centres as those used for milling.
Abstract: In this paper, the use of the ball burnishing process to improve the final quality of form tools (moulds and dies) is studied This process changes the roughness of the previously ball-end milled surfaces, achieving the finishing requirements for plastic injection moulds and stamping dies Ball burnishing can be easily applied in the same machining centres as those used for milling In this way, both lead times and production costs can be dramatically reduced Both the burnishing system and its main parameters are taken into account, considering their influence on finishing Workpiece surface integrity is ensured due to the surface smoothing effect of process and the associated cold working Examples of different materials, machined surfaces, and industrial applications are explained, with respect to the maximum and mean surface roughness achieved The main conclusion is that using a large radial depth of cut in the previous ball-end milling operation, together with a small radial depth during burnishing can produce acceptable final roughness Savings of production times are high, as burnishing is applied using the maximum linear feed of the machine, while milling must be made at moderate feeds Moreover, ball burnishing NC programming is less critical and needs less care in its definition than CAM for milling
108 citations
TL;DR: In this article, the impact of burnishing speed, burnishing force and burnishing tool dimension on the surface qualities and tribological properties were investigated, and it was found that a simple tool with interchangeable adapter for ball and roller were designed and fabricated to perform roller burnishing processes on Aluminium 6061 under different parameters and different burnishing orientations.
107 citations
TL;DR: In this article, the authors developed a device for mechanical plastic deformation of structural Rb40 steel using ball and roller burnishing and investigated the evolution of associated roughness, hardness and wear resistance.
99 citations
TL;DR: In this paper, the use of the ball burnishing process to improve the final quality of Inconel 718 surfaces is studied and the results of different tested pieces are discussed in relation to the maximum and mean surface roughness achieved microstructure and surface hardness.
Abstract: In this paper the use of the ball burnishing process to improve the final quality of Inconel 718 surfaces is studied. This process changes the roughness and residual stresses of the previously end milled surfaces, achieving the finishing requirements for engine components. Both the burnishing system and main parameters are taken into account, considering their influence on finishing. Workpiece surface integrity is ensured due to the compression effect of this surfacef enhancement process and its associated cold working. Results of different tested pieces are discussed in relation to the maximum and mean surface roughness achieved microstructure and surface hardness. Results of heat-treated low carbon mould steel P20 (32 HRC) are compared with those for the nickel alloy Inconel 718 (solution treated and age hardening, 40 HRC). The main conclusions are that using a large radial width of cut in the previous end milling operation, together with a small radial width of cut during burnishing can produce acceptable final roughness. And compression cold working is higher and deeper in the Inconel 718 than in the steel case.
85 citations
TL;DR: In this paper, the influence of ball-burnishing on residual stress profile of a 15-5PH martensitic stainless steel was investigated to understand their influence on the residual stress profiles in axial and circumferential directions.
Abstract: Ball-burnishing is a superfinishing process commonly applied to improve the surface integrity (surface roughness, residual stress, microstructure, hardness) of a mechanical component. This paper focuses on the influence of ball-burnishing on residual stress profile of a 15-5PH martensitic stainless steel. After a preparation of the surfaces by turning, various burnishing parameters were investigated to understand their influence on the residual stress profiles in axial and circumferential directions. It is highlighted that burnishing induces an intense and deep compressive layer. Among the ball-burnishing process parameters, the normal force is the most sensitive ones to modify the thickness of the affected layer and the peak of compression in the sub-surface, whereas the speed, the feed and the number of passes have a limited influence on the residual stress profiles.
83 citations
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TL;DR: Hard roller burnishing as mentioned in this paper transforms tensile residual stresses present in the surface zone after hard turning into compressive residual stresses, and has no effect on the formation of white layers.
Abstract: In a hard roller burnishing operation, a hydrostatically borne ceramic ball rolls over the component surface under high pressures The roughness peaks are flattened and the quality of the workpiece surface is improved When combined with hard turning, this process provides a manufacturing alternative to grinding and honing operations The studies determined optimum working parameter ranges Parameter settings were shown to be non-critical in this process, since constant surface qualities were attainable over wide setting ranges A second phase of the studies examined the improvements obtained for various original roughnesses Reductions of 30 to 50 % in mean peak-to-valley height Rz are, for example, achievable, depending on the original roughness Structure analyses and residual stress measurements were used to examine the effects of the process on the workpiece surface zone Hard roller burnishing transforms tensile residual stresses present in the surface zone after hard turning into compressive residual stresses Hard roller burnishing has no effect on the formation of white layers in the surface zone
151 citations
TL;DR: In this paper, the effects of ball-burnishing parameters on the surface roughness of AISI 1045 specimens were analyzed using the analysis-of-variance technique and the F-test.
81 citations
TL;DR: In this article, Liu et al. proposed that the residual stress profile along the depth is a polynomial function of the depth, and the coefficients of this residual stress are in turn functions of the machining parameters.
77 citations
TL;DR: In this article, the effects of ball burnishing parameters on the surface hardness of flat AISI 1045 specimens were investigated and it was shown that the following parameters have significant effects on surface hardness: depth of penetration, feed, lubricant and ball material.
48 citations
TL;DR: In this paper, the effects of five burnishing parameters (i.e., the roughness of the pre-burnished surface, the type of ball material, the depth of penetration, the burnishing speed, and type of lubricant) on the surface finish of AISI 316L stainless steel was studied.
47 citations