Showing papers on "Roller burnishing published in 2016"

Effect of roller burnishing process parameters on the surface roughness and microhardness for TA2 alloy

Abstract: Rolling burnishing is an effective method to improve the surface integrity of the machined part. It not only increases the hardness of the machined surface but also reduces the surface roughness. In this paper, experimental studies are performed to investigate the influence of roller burnishing parameters (i.e., spindle speed, burnishing depth, and burnishing feed) on the surface roughness and microhardness of TA2 alloy. The aim is to model the relations between some relevant process parameters and the surface performances of surface roughness and microhardness after roller burnishing, which can give an optimum combination of process parameters to produce desired surface roughness and microhardness. To achieve this goal, by utilizing response surface methodology and Box-Behnken experimental design techniques, workable empirical models are developed to predict surface roughness and microhardness. Analysis of variance is applied to investigate the relationship between process parameters and the output responses. The validation tests are performed to evaluate the effectiveness of the model and the response surface optimization techniques. The results indicate that the prediction values of surface roughness and microhardness have good agreement with the experimental ones. Among the process parameters, the spindle speed and burnishing depth are the significant parameters for reducing the surface roughness and raising the surface microhardness. Meanwhile, the experimental results also indicate that the roller burnishing process can obviously enhance the surface performances, which can lead to the reduction of surface roughness by 63 % and the increase of microhardness by 28 % compared to pre-machined surfaces.

Experimental investigation of effect of roller burnishing process parameters on surface roughness and surface hardness of C40E steel

Abstract: Surface finish and dimensional accuracy are ever in demand because of strong influence of these characteristics on major functional properties like friction, fatigue strength, wear resistance, load carrying capacity, and corrosion resistance of any materials. In the present work the effect of burnishing process parameters like burnishing condition, burnishing speed, feed, depth of penetration, number of passes is investigated on the surface roughness and hardness of C40E steel. Taguchi design of experiment is used for present experimentation. Taguchi's L18 mixed orthogonal array is used for optimisation of input parameters and analysis of variance (ANOVA) is employed for concluding vital and fruitful results. Investigation reveals that minimum surface roughness value of .129 µm at wet burnishing condition .557 rpm speed, .06 mm/rev feed, 1.5 mm depth of penetration and double pass of tool and optimised surface hardness 94 HRB at dry burnishing condition, 371 rpm speed, 0.11 mm/rev feed, 1.5 mm depth of penetration and third pass of tool is obtained.

Experimental Investigation of the Influence of Burnishing Parameters on Surface Roughness and Hardness of Brass Alloy

Abstract: Burnishing is a cold working surface finishing process in which peaks and valleys on machined surfaces deformed plastically by the application of hard and finished ball or roller against to it. Recently burnishing is becoming popular among post finishing processes because of its many advantages along its primary role i.e., increasing surface finish. In this paper the effect of burnishing process parameters on surface roughness and hardness of brass alloy is experimentally investigated. A simple roller burnishing tool was used for the experiential work of the present study, surface test and micro hardness test were used to demonstrate the effects of the burnishing force and feed rate on surface roughness and surface hardness of a brass alloy. The smoothing process under consideration can be performed on standard machine tools without additional reconfiguration tasks. Process is very useful for any workshop and can be carried out without coolant. The results proved that all the parameters have significant effect on the above said two surface characteristics. The results revealed that improvements in the surface finish and increase in the surface hardness are obtained by reduce the burnishing feed and increase the burnishing force.

Implementation of Taguchi Method in the Optimization of Roller Burnishing Process Parameter for Surface Roughness

Abstract: Need of industrial growth for developing country gives rapid acceleration in the field of technical research. Industries are very much aware of producing mechanical component with good surface quality without allowing a margin of error. Among the different challenges of industry, surface quality is the key factor now a day’s which can be improved by a novel after machining process known as burnishing process. This paper is mainly concerned with the effect of different process parameter on the surface roughness of aluminum alloy and the optimization of response measure. To achieve the goal of proposed work first pilot experiment is intended to ascertain the range of different parameters required for the experimental design methodology. Analysis of variance and signal to noise ratio are applied as statistical analysis to find out the significant control factor and optimize the level. The result shows the optimum set of process parameter having a value of 850 RPM spindle speed, 8 mm interference, 0.024 mm/rev feed and 4 no. of tool pass predict 0.010 µm surface roughness value which is having a greater agreement with the experimental value.

Influence of Roller Burnishing Parameters on Depletion of Plasticity Reserve

Abstract: Roller burnishing process considerably increases surface quality and service life of machine parts. Efficiency of roller burnishing rises greatly when technological inheritance (TI) is taken into account. Research results of degree of plasticity reserve depletion (DPRD) while roller burnishing are presented. Results obtained made it possible to establish mechanisms of strain accumulation and plasticity reserve depletion according to roller burnishing parameters.

Optimizing the Process Parameters and Investigating the Influence of Shot Peening and Roller Burnishing On Surface Layer Properties and Fatigue Performance of Al 6061 T4

Abstract: Abstract: In many industrial applications either in the automotive industry or structural applications, appears Al 6061 as a good choice from both economical and mechanical aspects. In this research, an Aluminium alloy (Al6061) was used and processed by shot peening and roller burnishing. A set of parameters were studied to optimize the parameters of each process and meet an enhanced fatigue life. With Almen intensities, 0.105, 0.141, 0.159, 0.173, 0.193, 0.222 and 0.229 mmA samples were prepared and tested by rotating beam fatigue. Microhardness test, residual stresses measurements, and fatigue life values showed that Almen intensity 0.193 mmA provides an increase 36% in fatigue strength. Roller burnishing process was carried out under different burnishing pressures varied from 0.3 to 1.2 bar. Results indicated that increasing burnishing pressure up to 0.8 bar led to an increase in fatigue strength with 61% higher than electropolished samples.

Roller burnishing tool

Abstract: The present invention reduces the number of components and achieves compactness by simplifying a structure, and improves maintenance. The present invention relates to a roller burnishing tool (1) having: a shank (2) mounted on a machine tool; a housing (3) which is connected to the shank, a connected position of the housing relative to the shank being adjustable; a roller support member (5) which has a cyclic cross section to follow a movement of the housing while being supported to be capable of rotating relative to the housing (3); a tapered roller (51) supported by the roller support member; and a mandrel (6) having a tapered part matched with the tapered roller. The roller burnishing tool comprises a tool diameter following device (8) connecting the shank (2) and the mandrel (6). And the tool diameter following device (8) comprises: a lead groove (24) which is prepared in a spiral shape on a cylindrical shape part formed at an end of the shank (2); a pin member (81) which is installed to be freely movable in a spiral shape along the lead groove (24); a pin member insertion hole (62b) which is formed in the mandrel (6) and is inserted with a pin member (81); and a biasing unit (82) which is mounted at the shank (2) and applies force to the mandrel (6) forward.

Influence of Burnishing Conditions on Burnishing Force and Application of Coated Roller in Inclined Roller Burnishing

Abstract: The influence of burnishing conditions on the burnishing force in the inclined roller burnishing method, which was developed by the authors, is investigated. The wear behaviors of non-coated and TiN- and Diamond-Like-Carbon-coated rollers and the effect of the coated roller on the inclined roller burnishing were also investigated. A round bar of carbon steel and an aluminum-based alloy were used as the workpiece material. The burnishing force was measured by a strain-gauge type 3-component dynamometer. The burnishing force component, which acts in the circumferential direction of the workpiece, increased with increasing inclination angle of the roller. Improvement of the tool life of the roller was obtained with a TiN-coated roller on which nitriding treatment of the base roller was performed prior to TiN coating. A satisfactory burnished surface was obtained by burnishing with the DLC-coated roller.

The Effect of Annealing Temperature and Roller Burnishing on the Microhardness and Surface Quality of AISI 3115 Alloy Steel

Abstract: This study presents the effect of annealing and roller burnishing processes on the surface properties of AISI 3115 alloy steel. This steel was heat-treated at a temperature range of (700-850)°C, then left to cool inside the furnace. After that the steel was burnished with different forces, feeds and burnishing speeds. The microhardness, average surface roughness and microstructure were investigated. The experimental results of annealing revealed that hardness increases as the annealing temperature increase, where the burnishing results revealed that microhardness increases with increasing the applied force and feed. However, increasing the spindle speed increases the microhardness to certain limit. After that, any increase in spindle speed results in a decrease in the microhardness. The effect of burnishing process on the surface roughness was also studied. The results showed that surface roughness decreases with increasing of force and with feed up to certain limit and inversely with increasing of spindle speed.

The influence of milling-burnishing successive and simultaneous processes on the surface roughness

Abstract: The present techniques do not offer the possibility for milling and burnishing at the same time. The novelty of this study is the development of a new tool and tool holder that allows this processes to take place simultaneous. Magnesium alloys have a wide range of usages in industry; in the past years they seem to be a promising solution to classic implants. Improvements in fatigue and tensile strength need to be made. Heat treatments are difficult to implement, so the solution is a mechanical treatment. The burnishing process offers very good results, but it has difficulties in simultaneous machining with the milling process. Thereby a hydraulic roller burnishing tool and a special tool holder was manufactured to solve this issue. The combined process was carried out on a CNC milling machine. This study seeks to highlight the influence of the milling-burnishing process parameter on the surface roughness in the case of magnesium alloy AZ31B-F. Parameters like speed and feed of cut, burnishing pressure and depth where taken into consideration. It was noted that with the increase of the feed, speed, pressure and depth of burnishing the general percentage improvement of the surface roughness was higher.

Slide member texture processing method, and slide member

Abstract: PROBLEM TO BE SOLVED: To provide a texture processing method capable of forming a texture pattern excellent in form accuracy by a novel method.SOLUTION: A scribing wheel 11 having a tip formed along a circumference ridge line is used, and the wheel 11 is rolled while pushing its edge onto the sliding face of a slide member 3 to be processed, so that a plastic deformation by a roller burnishing is caused to form the rolling traces of fine grooves 10, 10' and 10" in the sliding face thereby to process a texture pattern.SELECTED DRAWING: Figure 4

Parametric optimization of roller burnishing process for surface roughness and surface hardness

Abstract: Now a days, manufacturing industry expected more service life of the components without increasing the production cost This led to development improvised and versatile manufacturing processes that address these expectations The service behavior and life of the components depend mostly on the surface properties For this reason, significant attention has been paid to the post-machining operations, because the conventional machining processes like turning, milling etc produce surfaces with inherent irregularities and imperfections So there is need for a surface finishing operation that nullifies these irregularities Burnishing is one of the surface finishing process, which does not involve material removal, but improves the surface properties by deforming the surface plastically Here SS410 steel is used for making shafts with good surface finish and hardness by the roller burnishing process The present study aims to achieve high performance of roller burnishing machine, experiments is carry out to find effect of input parameter on output performance parameter The experimental data will be optimizing by full factorial methodology, and conclude optimal set of parameter by Response surface methodology or Regression analysis

Planetary rolling contact gear unit, and method for manufacturing same

Abstract: Disclosed is a planetary rolling contact gear unit (1) comprising a rotatably driven spindle shaft (2) mounted by means of a support bearing (9), a spindle nut (4) which can be axially moved by the spindle shaft (2) and is mounted in a rotationally fixed manner, and a plurality of planetary rolling elements (6) which are placed between the spindle nut (4) and the spindle shaft (2) and are able to roll; a bearing collar (21) for the support bearing (9) is formed using a roller burnishing process.

Roller burnishing tool

Abstract: The invention discloses a roller burnishing tool, which comprises a tool bar. A groove matched with a bush is formed in a surface of one end of the tool bar; the bush is provided with a blind hole in close fit with a steel ball; and a portion, exposed from an orifice of the bush, of the steel ball is less than 1/2 of a diameter of the steel ball. The bush is made of a polytetrafluoroethylene material or engineering plastics. The roller burnishing tool has the remarkable advantage of low cost because of satisfaction of a finish requirement without additional rolling equipment.

The Numerical Analysis of Burnishing Process of Hollow Steel Tubes

Abstract: This paper presents numerical research of burnishing process of hollow steel tubes. The internal surfaces of the tubular elements are treated, among others, by burnishing process. The type of force can be divided into static and dynamic burnishing. The kinematics can be divided into sliding and roller burnishing. Occurrence of moving parts in direct contact with the material qualifies for the group process of burnishing rolling. The sliding burnishing design element property is part of the work surface burnished permanently attached to the handle. Theoretical analysis of the burnishing is carried out numerically. For the calculations were used commercial software Forge based on the finite element method. After burnishing modeling was found intentionally controlled state of stress and strain in the tubular elements to ensure the intended technological quality.

Investigations on Effect of Abrasives in Ball and Roller Burnishing Process

Abstract: Burnishing is process in which irregularities on machined surface deformed plastically using hard ball or roller. The deforming action of the ball of roller fills peaks into valleys due to which properties at surface improves along with surface finish. In present work ball and roller burnishing process is carried out on cylindrical components of free cutting brass in presence of abrasive particles of 20/40 micro coarser size in the form of paste (paste) and its effect studied on surface roughness and micro hardness. Two parameters namely burnishing force and speed were controlled during burnishing process. It was found that the application of paste in between specimen and tool interface is advantageous in case of ball burnishing where as in case of roller burnishing the results were adversely affected by paste.

Manufacturing of Twist-Free Surfaces by Magnetism Aided Machining Technologies

Abstract: Abstract—As a well-known conventional finishing process, the grinding is commonly used to manufacture seal mating surfaces and bearing surfaces, but is also creates twisted surfaces. The machined surfaces by turning or grinding usually have twist structure on the surfaces, which can convey lubricants such as conveyor screw. To avoid this phenomenon, have to use special techniques or machines, for example start-stop turning, tangential turning, ultrasonic protection or special toll geometries. All of these solutions have high cost and difficult usability. In this paper, we describe a system and summarize the results of the experimental research carried out mainly in the field of Magnetic Abrasive Polishing (MAP) and Magnetic Roller Burnishing (MRB). These technologies are simple and also green while able to produce twist-free surfaces. During the tests, C45 normalized steel was used as workpiece material which was machined by simple and Wiper geometrical turning inserts in a CNC turning lathe. After the turning, the MAP and MRB technologies can be used directly to reduce the twist of surfaces. The evaluation was completed by advanced measuring and IT equipment.

The influence of milling-burnishing successive and simultaneous processes on the material hardness

Abstract: Recent developments in the field of bio-engineering allow the use of magnesium alloys as a substitute for medical implants. The issue with such alloys is the degradation rate witch has to be improved in order to provide the necessary support for the entire duration of the bone fraction healing. For improving the bone shielding heat treatment does not represent a solution, but chemical and/or mechanical do. One mechanical process that has excellent result is burnishing, but this process is difficult to be implemented on a milling machine. Therefore, it was necessary that a new tool and tool holder to be developed, that allow the simultaneous process to take place. A high-pressure hydraulic roller burnishing tool with a special tool holder was used on a CNC milling machine. The material used for this study is magnesium alloy AZ31B-F, and one of the main purposes was to improve the material hardness (HV). The milling-burnishing parameters that where varied are the speed and feed, burnishing pressure and depth, type of process (successive or simultaneous), machining direction and the material hardness after milling. The results were analyzed as percentage improvement between the milling and burnishing measured values.

Roller burnishing processing device

Abstract: PROBLEM TO BE SOLVED: To provide a roller burnishing processing device capable of heightening processing efficiency of the outer peripheral surface of a shaft part of a crank shaft by a simple constitution, while avoiding interference of a balance weightSOLUTION: A roller burnishing processing device 10 includes a pair of burnishing rollers 14, 16 extending along the axial direction of a crank shaft 100, a pressing mechanism 18 and a support part 20 The pressing mechanism 18 has a first backup roller 22, and the burnishing rollers 14, 16 have a contact with a shaft part 102 in the juxtaposed state along the circumferential direction of the shaft part 102 of the crank shaft 100SELECTED DRAWING: Figure 2

Method of texturizing a sliding member and the sliding member

Abstract: The present invention provides a texturizing method which can form texture patterns having excellent figure accuracy by a new method. The texturizing method uses a scribing wheel (11) having bits along an outer circumference thereof. The bits of the scribing wheel (11) adhere to the sliding surface of a sliding member (3) to be processed, and are rolled to form the rolling track of minute grooves (10, 10, 10) on the sliding surface by generating plastic deformation by roller burnishing; thereby texturizing the sliding surface of the sliding member.

Roller burnishing device

Abstract: PROBLEM TO BE SOLVED: To provide a roller burnishing device which enables improvement of the processing efficiency of an outer peripheral surface of a shaft part of a crank shaft with a simple structure while avoiding interference of a balance weight.SOLUTION: A roller burnishing device 10 includes: a pair of burnish rollers 14, 16; a backup roller 22; and a support part 20. The support part 20 has: a support part body 55; a pair of first rollers 56, 58; a pair of second rollers 60, 62 which are disposed so as to sandwich the pair of first rollers 56, 58; and multiple bearings which are provided at the support part body 55 and rotatably support the respective second rollers 60, 62 in a state where outer peripheral surfaces 60a, 62a of the respective second rollers 60, 62 are separated from the support part body 55.SELECTED DRAWING: Figure 3