Showing papers on "Roller burnishing published in 2018"
TL;DR: In this article, the surface characteristics of roller burnishing processes are investigated to decrease the machining costs and time, and the nonlinear re-linear surface characteristics are systematically investigated.
Abstract: Improving the surface characteristics of roller burnishing processes is one of effective approaches to decrease the machining costs and time. This paper systematically investigates the nonlinear re...
35 citations
TL;DR: In this article, the surface modifications of Al(B4C)p Metal Matrix Composites (MMC) workpiece material after burnishing with a TiAlN coated WC roller were studied.
Abstract: Burnishing avoids the need for super finishing operations after the conventional turning process, to enhance the surface quality. This paper deals with the surface modifications of Al(B4C)p Metal Matrix Composites (MMC) workpiece material after burnishing with a TiAlN coated WC roller. The burnishing speed, lubrication type, burnishing passes, and coating were the input parameters. Surface hardness and roughness after the burnishing were studied. It was found that the coating on the WC roller had enhanced the hardness in the workpiece after burnishing in the case of Al-5 wt.% (B4C)p, under all conditions. The effect of the coating on the work piece surface hardness was not significant with Al-10 wt.% (B4C)p. While burnishing Al-5 wt.% (B4C)p, the minimum surface roughness combined with maximum surface hardness was obtained, during the third pass under dry condition using uncoated rollers. The number of passes to achieve the desired surface conditions reduced, on using coated rollers with kerosene ...
17 citations
TL;DR: In this paper, an optimization of roller burnishing process in CNC machining center has been discussed using response surface methodology (RSM) collectively with desirability function approach (DFA).
Abstract: In the present study, an optimization of roller burnishing process in CNC machining centre has been discussed using response surface methodology (RSM) collectively with desirability function approach (DFA). Response surface methodology is a statistical technique used to model and optimize the response. Using a rotatable central composite design (CCD) of RSM, model was developed to predict surface roughness. Burnishing speed, Interference, Feed and No of tool pass were considered as model variables to develop the predictive models. Experiments were conducted on Aluminium alloy 6061 work material based on five-level design with spindle speed, interference, feed, and number of tool pass as model variables to develop the predictive models. The results indicated that Interference and feed were the most significant factors on the surface roughness. The validity of the predicted model has been confirmed by performing verification experiments under the optimal conditions. Results of the experimentation at the optimum process parameter combination confirm the effectiveness of the developed model using response surface method for optimum burnishing parameters.
16 citations
TL;DR: In this article, a tool is fabricated which has the ability to vary the pressure accordingly and tests are conducted to evaluate the variation of hardness and roughness parameter with speed and pressure on the given specimen.
14 citations
27 Jan 2018
TL;DR: In this article, the surface properties in the roller burnishing of AMCs were investigated by applying different contact forces and feeds, and the results showed that the lowest surface roughness values were achieved with the smallest feed (0.05 mm) and the highest contact force (750 N) tested.
Abstract: Energy and resource efficient systems often demand the use of light-weight materials with a specific combination of properties. However, these requirements usually cannot be achieved with homogeneous materials. Consequently, composites enabling tailored properties gain more and more importance. A special kind of these materials is aluminium matrix composites (AMCs), which offer elevated strength and wear resistance in comparison to the matrix alloy. However, machining of these materials involves high tool wear and surface imperfections. An approach to producing high-quality surfaces consists in roller burnishing of AMCs. Furthermore, such forming technologies allow for the generation of strong compressive residual stresses. The investigations address the surface properties in the roller burnishing of AMCs by applying different contact forces and feeds. For the experiments, specimens of the alloy AA2124 reinforced with 25% volume proportion of SiC particles are used. Because of the high hardness of the ceramic particles, roller bodies were manufactured from cemented carbide. The results show that roller burnishing enables the generation of smooth surfaces with strong compressive residual stresses in the matrix alloy. The lowest surface roughness values are achieved with the smallest feed (0.05 mm) and the highest contact force (750 N) tested. Such surfaces are supposed to be beneficial for components exposed to dynamic loads.
13 citations
30 Nov 2018
TL;DR: In this paper, the effect of different burnishing strategies on a C45 steel machining was investigated, and the results showed that all different strategies have special application areas where they can be used efficiently (e.g. sliding surface, molding tool and after- or pre-machining for ultra-precision machining).
Abstract: The aim of this paper is to investigate the effect of different burnishing strategy on a C45 steel machining. Burnishing is a well-known, cold working surface improving technology, it is usually applied for cylindrical workpiece. In the reported research a novel developed magnetic assisted ball burnishing (MABB) tool was applied which was designed for MABB machining of flat and harmonic surfaces. To increase its efficiency, different types of machining strategies were applied. After the burnishing process the machined surfaces were measured by surface roughness tester to determine the most important Rsk and Rku tribological parameters. According to the results it can be stated that all different burnishing strategies have special application areas where they can be used efficiently (e.g. sliding surface, moulding tool and after- or pre-machining for ultra-precision machining).
12 citations
TL;DR: In this article, the authors used the response surface methodology (RSM) to fit the quadratic model for surface roughness and micro-hardness of roller burnishing process on Aluminum alloy 63400 Grade.
11 citations
03 May 2018
TL;DR: In this paper, an analysis of the depth of the plastically deformed layer in the process of roller burnishing a shaft using a newly developed method in which a braking moment is applied to the roller is presented.
Abstract: The subject of this paper is an analysis of the determination of the depth of the plastically deformed layer in the process of roller burnishing a shaft using a newly developed method in which a braking moment is applied to the roller. It is possible to increase the depth of the plastically deformed layer by applying the braking moment to the roller during the burnishing process. The theoretical considerations presented are based on the Hertz-Bielayev and Huber-Mises theories and permit the calculation of the depth of plastic deformation of the top layer of the burnished shaft. The theoretical analysis has been verified experimentally and using numerical calculations based on the finite element method using the Msc.MARC program. Experimental tests were carried out on ring-shaped samples made of C45 carbon steel. The samples were burnished at different values of roller force and different values of braking moment. A significant increase was found in the depth of the plastically deformed surface layer of roller burnished shafts. Usage of the phenomenon of strain hardening of steel allows the technology presented here to increase the fatigue life of the shafts.
8 citations
TL;DR: In this article, AA6063 cylindrical rods of 2 feet long and 25mm outer diameter are taken and a hardened steel roller is made as a tool and pressed against a rotating cylinrical work piece and parallel to the axis of the work.
7 citations
TL;DR: In this paper, a multi-response for roller burnishing process for an optimum parametric combination to yield favorable surface roughness and surface hardness using the Grey relational analysis and Taguchi method on aluminum alloy 6061 work material.
6 citations
TL;DR: In this article, the influence of surface plastic deformation (SPD) on the properties of the surface layer of a part “guide apparatus” of the centrifugal submersible pump for oil production was investigated.
Abstract: This paper presents experimental studies of the influence of surface plastic deformation (SPD) (roller burnishing) on the properties of the surface layer of a part “guide apparatus” of the centrifugal submersible pump for oil production. The parts made of composite powder alloys based on the iron-copper system were taken as an object of researches. The microstructure of the surface layer of the samples, surface roughness, microhardness, and hardness were studied. Testing of the samples for the surface layer resistance to abrasive wear according to the Calotest method showed a decrease in the wear intensity by 1.5–1.6 times in comparison to samples without SPD.
TL;DR: In this article, an adaptive neuro-fuzzy inference system was applied to anticipate the workpiece hardness and surface roughness after the roller burnishing process, including burnishing depth, feed rate, speed, roller width, and lubrication mode.
Abstract: Polymers are utilized in numerous tribological applications because of their excellent characteristics; for example, accommodating shock loading and shaft misalignment. A high surface finish is required to ensure consistently good performance and extended service life of manufactured polymeric components. Burnishing is the best choice as a finishing process for this study due to its ability to increase hardness, fatigue strength, and wear resistance and also introduce compressive residual stress on the burnished workpiece. Due to the complexity and uncertainty of the machining processes, soft computing techniques are preferred for anticipating the performance of the machining processes. In this study, ANFIS as an adaptive neuro-fuzzy inference system was applied to anticipate the workpiece hardness and surface roughness after the roller burnishing process. Five burnishing variables, including burnishing depth, feed rate, speed, roller width, and lubrication mode, were analyzed. A Gauss membership ...
01 Jan 2018
TL;DR: In this article, an experimental work was carried out on various Aluminium alloys, such as Al 2014 and Al 6063 using different burnishing parameters such as cutting speed, feed, no of passes and depth of cut using burnishing tool.
Abstract: Roller burnishing is one of the surface finishing processes without removing of a material, where a roller rolls over the machined surface under high pressure and flattens, the roughness peaks into valley. It will improve surface finish, as well as enforces favorable compressive residual stresses and raises hardness in functional surfaces. Aluminium alloys find attractive alternate for high strength applications. In this experimental work, burnishing operation is carried out on various Aluminium alloys, such as Al 2014 and Al 6063 using different burnishing parameters, such as cutting speed, feed, no of passes and depth of cut using burnishing tool. Through this experimental work, parameter that affects the surface roughness and surface hardness, on Al 2014 and 6063 material was identified and its influence on these responses was discussed. Also, the studies include the application one of the machine learning techniques is fuzzy logic, in the aspects of modeling and optimization of various process parameters applied, with roller burnishing process. This would give the comprehensive idea on choosing an optimum burnishing condition.
TL;DR: The influence of burnishing conditions on burnished-surface quality was investigated, and surface quality was evaluated based primarily on the surface roughness, surface profile, and external appearance.
Abstract: Burnishing characteristics of a newly developed roller burnishing method were developed. The developed method can effectively control the sliding direction between the roller and a cylindrical workpiece by inclining the roller axis with respect to the workpiece axis. The outer surface of a round aluminum alloy bar was targeted. The influence of burnishing conditions on burnished-surface quality was investigated, and surface quality was evaluated based primarily on the surface roughness, surface profile, and external appearance. As observed, the burnished-surface quality was strongly influenced by the pressing force, roller-inclination angle, and number of tool passes. A superior surface quality could be realized by increasing the number of tool passes.
30 Jul 2018
TL;DR: The aim of this work is to optimize the roller burnishing process parameters for minimizing the surface roughness using response surface methodology (RSM) and lion optimization algorithm.
Abstract: The aim of this work is to optimize the roller burnishing process parameters for minimizing the surface roughness using response surface methodology(RSM) and lion optimization algorithm. A RSM based box-behnken design is utilized for experimentations. The empirical model of surface roughness is developed for showing the relation between inputs and output of the burnishing process. The analysis of variance (ANOVA) method was used to check the accuracy of the developed mathematical model. With the developed mathematical model, the roller burnishing process parameters were then optimized to minimize the surface roughness by a new type of lion optimization algorithm. Further, validation test has been conducted for the optimal conditions suggested by lion optimization algorithm. The experimental value agreed with those predicted value with 3.225 of relative error percentage.
TL;DR: In this article, the effect of abrasive particles in the burnishing process was examined and a 24 full factorial design was adopted to develop the mathematical model for surface roughness regarding four process parameters.
Abstract: Roller burnishing process was carried out on free cutting brass materials in the presence of fine silicon carbide abrasives in the form of paste on a pre-machined surface. The results of ‘without-paste’ burnishing (plain burnishing, PB) and ‘with-paste’ burnishing (abrasive assisted burnishing, AAB) processes are compared to examine the effect of abrasive particles in the burnishing process. A 24 full factorial design is adopted to develop the mathematical model for surface roughness regarding four process parameters like burnishing force, burnishing speed, burnishing feed and number of passes for both the cases, i.e. PB and AAB. Analysis of variance (ANOVA) was carried out to find the effect of process parameters and to check the adequacy of the models. The results show that the parameters have a significant effect on the response in PB to improve the surface roughness by 75 % than the turned components. Whereas in AAB, fine abrasive particles as a single entity controlling the response and making other parameter effects as non-significant. Surface roughness further improved by 15 % in AAB process.
TL;DR: In this paper, the authors presented the methods used to determine the depth of the plastically deformed top layer in the roller burnishing process, and the results of deformation depth as a function of roller force, material strength and roller geometry show a good agreement between analytical and experimental methods.
Abstract: This paper presents the methods used to determine the depth of the plastically deformed top layer in the roller burnishing process. An analytical method was developed for determining the depth of the plastically deformed layer on the basis of the Hertz–Bielayev theory. The depth of deformation was obtained as a function of the process parameters: burnishing force, material strength and roller radius. The analytical solution has been verified using an original method based on the measurement of the face profile of rings. A mathematical model for a theoretical solution and a plan for experimental tests have been developed. The numerical simulation of the depth of the plastically deformed layer was carried out based on the finite element method. The results of deformation depth as a function of roller force, material strength and roller geometry show a good agreement between analytical and experimental methods.
Posted Content•
TL;DR: In this paper, an experimental work was carried out on various Aluminium alloys, such as Al 2014 and Al 6063 using different burnishing parameters such as cutting speed, feed, no of passes and depth of cut using burnishing tool.
Abstract: Roller burnishing is one of the surface finishing processes without removing of a material, where a roller rolls over the machined surface under high pressure and flattens, the roughness peaks into valley. It will improve surface finish, as well as enforces favorable compressive residual stresses and raises hardness in functional surfaces. Aluminium alloys find attractive alternate for high strength applications. In this experimental work, burnishing operation is carried out on various Aluminium alloys, such as Al 2014 and Al 6063 using different burnishing parameters, such as cutting speed, feed, no of passes and depth of cut using burnishing tool. Through this experimental work, parameter that affects the surface roughness and surface hardness, on Al 2014 and 6063 material was identified and its influence on these responses was discussed. Also, the studies include the application one of the machine learning techniques is fuzzy logic, in the aspects of modeling and optimization of various process parameters applied, with roller burnishing process. This would give the comprehensive idea on choosing an optimum burnishing condition.
19 Nov 2018
TL;DR: In this paper, a new chamber boring tooling system was developed in order to machine the bore hole wall as well as the bottom of a cylindrical bore hole, which can be executed on the same single tube system with the same component set-up.
Abstract: Deep hole drilling is a machining process for the production of cylindrical bore holes with a large length-to-diameter ratio. A special deep hole drilling process called chamber boring was developed for the production of contoured bore holes in axial direction [1]. For special applications not only the contouring in axial directions is required but also the contouring of the bore hole bottom. Therefore, a new chamber boring tooling system was developed in order to machine the bore hole wall as well as the bore hole bottom. Due to an exchangeable system of different tool sliders, even the surface finishing and treatment by roller burnishing becomes feasible. All processes, the STS (Single Tube System) deep hole drilling, the final machining and the roller burnishing can be executed on the same deep hole drilling machine with the same component set-up.
08 Nov 2018
TL;DR: In this article, a vibrational-centrifugal strengthening treatment is proposed to increase the lifetime of wheel hubs and flanges by forming compressive residual stress in the contact places in the part material.
Abstract: Technology, equipment, and results of stand tests of plane wheel hubs and flanges strengthened by surface plastic deformation are described. The new method suggested by the authors is called vibrational-centrifugal strengthening treatment. It belongs to the method group of dynamic strengthening of revolutional shape parts. It is based on impact interaction of the part processed with a massive tool which is rolled over the strengthened surface of the part when under vibration. Moreover, the impact contact between the part and the tool occurs through a small number of deformable bodies. This provides formation of compressive residual stress in the contact places in the part material. For magnesium wheel hubs (alloy ML-12) residual compressive stress is within 110 MPa, for aluminium ones (alloy AK6) it is within 250 MPa. The degree of strengthening of outer zone material for magnesium wheel hubs is 45...59 % with surface micro-hardness increasing up to 1150 N/m2 and the thickness of the strengthened layer being 0.9...1.0 mm. When strengthening aluminium wheel hubs and flanges, the thickness of the strengthened layer is to be 0.6...0.9 mm with a degree of cold work being 25...30 %. Fatigue studies of a party of KT-141 type wheel hubs strengthened by the method (magnesium alloy MT-12) demonstrated their service life increasing up to 1000 take-offs and landings at the safety coefficient of n = 3.5. The lifetime of this type of wheel hubs strengthened by roller burnishing did not exceed 750 take-offs and landings; for unstrengthened ones, it made 500 take-offs and landings at lower values of the safety coefficient. Strengthening the wheel hub web KT-150K (aluminium alloy AK6) increases their lifetime by 28...30 % on average. Apart from plane wheel hubs and flanges, the method of vibrational-centrifugal strengthening treatment can be applied for increasing the lifespan of various parts of chassis components of circular section, for strengthening nonferrous metal webs of car wheels, radius blends and steel shaft journals etc.
Journal Article•
TL;DR: In this article, the effect of machine parameters on a surface roughness in roller burnishing of aluminium alloy is explained and a design of experiments (DOE) is applied to study various burnishing parameters.
Abstract: In today’s time, the manufacturing of machines and other components with highly furnished surfaces are becoming more and more important. Surface finishing is the mandatory characteristic of any produces machine. Burnishing operation is getting evolved very frequently and it helps to improve surface roughness of machinery part easily. It basically involved plastic deformation of the material. It is cold rolling process without any removal of metal from the work piece. Peaks get changed into valleys and at last a highly polished mirror like surface is obtained. In case of sliding surfaces it enhances the life of the material. This paper explains the effect of machine parameters on a surface roughness in roller burnishing of aluminium alloy. In Experimentation, design of experiments (DOE) is applied to study various burnishing parameters on surface roughness.
01 Jan 2018
01 Jan 2018
TL;DR: In this paper, the results of roller burnishing parameters analysis with selfacting feed are presented in order to find the strongest influence on roller burnished surface roughness has initial surface roughs and burnishing velocity.
Abstract: The results of roller burnishing parameters analysis with selfacting feed are presented in this paper. Method of parameter process design based on the quality losses G. Taguchi function was applied. The following controlled parameters were assumed: Ra – roughness parameter before roller burnishing process, w interference between a roller and a burnished sample. k – multiplication factor of each sample point deformation, V – burnishing velocity. The following factors were assumed as process disturbances: treated material hardness and lubrication of burnished surface. Basing on experimental results it was found that strongest influence (in tested range of parameters variations) on roller burnished surface roughness has initial surface roughness and burnishing velocity. These factors also showed have the smallest resistance to process disturbances. 1 Theoretical introduction Basing on the achievements of mathematical statistics and classical methods of experimental design, Taguchi developer his own methods of experimental design and results analysis [1-4]. Taguchi created among the others theory of quality losses function based on experimental design. Decrease in the number of experiment with respect to traditional experiment is the fundamental advantage of Taguchi’s approach. However selection of suitable factors combination causes controversy. The roller burnishing is one of the most often used methods of burnishing of cylindrical outer surfaces. Usually it is used for cold hardening. Smoothness burnishing is the other application. This kind of burnishing is applied when required shape and dimensional accuracy was obtained in previous treatment and very good smoothness of burnished surface is required. Smoothness roller burnishing is used to finish machine parts in which grinding pollutions in surface layer are unacceptable or for elements which can’t be finished with too strong forces. For mentioned above elements ball burnishing or slide diamond burnishing are usually used. However these finishing methods are characterized by very small productivity and whenever possible the roller burnishing should be used because of its this higher productivity. In order to obtain higher shape-dimensional * Corresponding author: app@prz.edu.pl
01 Jan 2018
TL;DR: In this paper, a finite element analysis is done with the help of ANSYS software to analyse the stresses developed on the workpiece surface and the total deformation in workpiece.
Abstract: Burnishing is a super-finishing process which plastically deforms the surface non-uniformities to give a superior surface finish. In this process, the tool applies pressure over workpiece surface and this creates compressive stresses. To analyse these stresses the finite element analysis is done with the help of ANSYS software. The stresses developed on the workpiece surface and the total deformation in workpiece is found using this software.
30 Apr 2018
Journal Article•
TL;DR: In this article, the effect of input parameters such as feed rate, cutting speed, number of passes, burnishing force and cooling system which is applying by minimum quantity of lubrication (MQL) on surface roughness and micro-hardness in roller burnishing of Aluminum alloy 6061 has been investigated.
Abstract: Burnishing is a chip-less finishing process, in which a hard roller or ball presses the surface layer of part to perform plastic deformation in the surface layer and produce improved finish, enhanced hardness and compressive residual stresses on the surface of special materials such as Aluminum and Brass. In the following research, the effect of input parameters such as feed rate, cutting speed, number of passes , burnishing force and cooling system which is applying by minimum quantity of lubrication (MQL) on surface roughness and micro-hardness in roller burnishing of Aluminum alloy 6061 has been investigated. Taguchi method is used for design of experiments and special burnishing tool is used for this research. The optimization results show that the effect of feed rate and burnishing speed is significant on surface roughness and burnishing force and the number of passes plays important role in micro-hardness. The minimum surface roughness in burnishing of aluminum alloy 6061 was 0.138 μm and the maximum was 0.475 μm. The maximum micro-hardness in roller burnishing Aluminum alloy 6061was found 122 HB and the minimum was 100 HB.