Roller burnishing

About: Roller burnishing is a(n) research topic. Over the lifetime, 395 publication(s) have been published within this topic receiving 3322 citation(s).

An Investigation into Roller Burnishing

Abstract: Burnishing, a plastic deformation process, is becoming more popular as a finishing process: thus, how to select the burnishing parameters to reduce the surface roughness and to increase the surface microhardness is especially crucial This paper reports the results of an experimental program to study the influence of different burnishing conditions on both surface microhardness and roughness: namely, burnishing speed, force, feed, and number of passes Also, it reports the relationship between residual stress and both burnishing speed and force The residual stress distribution in the surface region that is orthogonally burnished is determined using a deflection etching technique Mathematical models are presented for predicting the surface microhardness and roughness of St-37 caused by roller burnishing under lubricated conditions Variance analysis is conducted to determine the prominent parameters and the adequacy of the models From an initial roughness of about Ra 45 μm, the specimen could be finished to a roughness of 05 μm It is shown that the spindle speed, burnishing force, burnishing feed and number of passes have the most significant effect on both surface microhardness and surface roughness and there are many interactions between these parameters The maximum residual stress changes from tensile to compressive with an increase in burnishing force from 5 to 25 kgf With a further increase in burnishing force from 25 to 45 kgf, the maximum residual stress increases in compression

The effects of ball- and roller-burnishing on the surface roughness and hardness of some non-ferrous metals

Abstract: Simple ball- and roller-burnishing tools were used for the experimental work of the present study, these tools being quite similar in their design principles. The performance of the tools, together with the effects of the burnishing force and the number of burnishing tool passes on the surface roughness and surface hardness of commercially available aluminum and brass, were studied. The results show that improvements in the surface roughness and increases in the surface hardness were achieved by the application of both ball burnishing and roller burnishing with the non-ferrous metals under consideration.

Roller burnishing of hard turned surfaces

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

Experimental techniques for studying the effects of milling roller-burnishing parameters on surface integrity

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.

Finite Element Modeling of Roller Burnishing Process

Abstract: Hard roller burnishing is a cost effective surface enhancement process where a ceramic ball rolls on the machined surface under a high pressure and flattens the roughness peaks. It not only improves surface finish but also imposes favorable compressive residual stresses and raises hardness in functional surfaces, which can lead to long fatigue life. Most research in the past focused on experimental studies. There is still a special need for a reliable finite element (FEM) model that provides a fundamental understanding of the process mechanics. In this study, 2D and 3D FEM models for hard roller burnishing were established. The simulation results (i.e. surface deformation and residual stress) were evaluated and compared between initial hard turned and burnished surfaces. The predicted residual stress was validated with the experimental data obtained from the literature.