Showing papers on "Roller burnishing published in 2019"

Optimization of roller burnishing process using Kriging model to improve surface properties

Abstract: The objective of this work is to investigate the influences of three machining factors (burnishing speed V, feed rate f, and depth of penetration a) on the improved rate of arithmetic average rough...

Application of GRA method for multi-objective optimization of roller burnishing process parameters using a carbide tool on high carbon steel (AISI-1040)

Abstract: The purpose of this paper is to analyze and optimize the roller burnishing process parameters using the design of experiments and grey relational analysis (GRA).,In this experimental work, the carbide burnishing tool has been selected for the machining of AISI-1040 high carbon steel to get better product quality and satisfactory machining characteristics. The material surface condition while machining, burnishing tool speed, feed rate, depth of penetration and No. of passes have been selected as process constraints to conduct experimental trials.,The surface roughness (SR) and surface hardness were considered as output responses. The experimental outcomes optimized by multi-parametric optimization showed considerable improvement in the process. The roller speed and number of passes are the most significant parameters for surface hardness, whereas the surface condition and roller penetration depth have the most significance on SR.,The GRA method shows the 0.03376 improvement in grey relational grade between the experimental values and the predicted values.,The experimental outcomes optimized by multi-parametric optimization showed the considerable improvement in the process and will facilitate steel industries to enhance and improve productivity while burnishing high carbon steel (AISI-1040).,This research represents valid work, and the authors have no conflict of interests.

Experimental Assessment of the Depth of the Deformed Layer in the Roller Burnishing Process

Abstract: This paper presents the methods of experimental determining the depth of the plastically deformed top layer in the roller burnishing process. Precise determination of the depth of the plastically deformed layer is difficult due to slight deformation at the boundary of the plastic and elastic zone, the lack of visible changes in the microstructure, and minimal changes in microhardness. The article shows the method of original measurement method that consists in determining the thickness of the deformed layer using rings. The method involves the profilographometric measurements of the disconnected rings (samples) which are flat-faced in the package on the mandrel. The rings material deforms plastically in the surface layer causing wrapping of the end face of the ring in the direction of the rolling tool movement. After dismantling the ring pack, measurements were made on the face of each ring along radial directions, and the thickness of the deformed layer was observed on the microscope. The method was verified by microhardness measurements in the cross-section and cross-section of the ring. The results of deformation depth measurements were verified by finite-element-based numerical simulation.

Investigation of Aluminum Alloy Properties During Helical Roller Burnishing Through Finite Element Simulations and Experiments

Abstract: Industry is always looking for ways to increase the lifetime of assemblies, especially the fatigue lifetime, from the production phase of fastening holes onwards. Helical roller burnishing is presented here as an innovative mechanical surface treatment. Applied directly after orbital drilling, this technique induces superficial plastic strains that reduce surface roughness and increase hardening and compressive residual stresses. Several studies on 3D finite element models of burnishing have been carried out but they are very time-consuming. In this review, a comparative numerical study of helical burnishing (in terms of calculation time and results on residual stress) between one 3D and two 2D plane strain finite element simulations is performed on 2024-T351 aluminum alloy drilled parts. The impact of the process operating parameters is also investigated. This comparison shows fairly similar results regarding the residual stress profiles but levels are rather different. This could be explained by the complex kinematics of helical roller burnishing, which is strongly three-dimensional. The numerical results of one of the cases studied reveal com-pressive residual stresses of around −100 and −490 MPa in the radial and circumferential directions of the hole, respectively. Burnishing depth and spindle rotation speed have a great impact on the final residual stress profiles. These simulations are then confronted with experimental results obtained during tests carried out using an orbital drilling unit (ORBIBOT). This demonstrates the interest of the modeling implemented and also points out ways to improve the developed models.

Influence of Tool Feed Conditions on Surface Integrity in Roller Burnishing with Rolling and Sliding Effects

Abstract: The influence of tool feed conditions on the burnished-surface integrity obtained by roller burnishing, which can generate the sliding effect, adding to the rolling effect at burnishing point, is addressed. A JIS SCM420 steel round bar was used as the workpiece. The surface integrity was improved by feeding the roller in the same direction with the sliding effect and by decreasing the tool feed rate. A better surface was achieved when the roller was fed in the opposite direction to the feed direction of the turning tool in a preceding process of the burnishing.

Analysis and Optimization of Surface Roughness and Microhardness for Roller Burnishing using Response Surface Methodology and Desirability Function Approach on Aluminum 63400

Abstract: In the present study, response surface methodology (RSM) has been used to optimize roller burnishing process for aluminum alloy 63400 grade. Single roller burnishing tool (carbide) is used to burni...

Application of irregular roller burnishing in the shaft straightening process - Experimental and numerical study

Abstract: This article presents the technology used for straightening large-dimension shafts through irregular burnishing. Irregular burnishing is performed on part of the cylindrical surface while the opposite surface is not burnished. The aim of straightening technology is to introduce squeezing stresses on the shaft surface, which cause the straightening and the increase in fatigue durability of this area. The significant parameters in the process of shaft straightening include: the depth δ of the plastically deformed surface, which determines the size of the squeezing stresses introduced in the surface layer and the length h of the burnished surface. This article presents the calculation method for the depth δ of a surface that is plastically deformed in the process of burnishing, as well as its experimental verification. The numerical modelling of roller burnishing has been carried out using the finite element-based MSC. Marc program. The method for the identification of the length of the burnished surface for straightening a shaft with a curvature f is described. The methodology is used to straighten a large-dimension shaft with a diameter of 292 mm and length of 3700 mm.

Roller burnishing tool

Abstract: The invention relates to a roller burnishing tool for generating a tooth structure in a wall (6.2) of a cylindrical blank (6), comprising the following features: • - a clamping device for holding the blank (6); • - an annulus of disc-shaped rotatably mounted rollers (1), the peripheral edges of which are directed against the wall (6.2) of the blank and are pressed against the same; • - bearing journal (2) for mounting the rollers (1); • - a stamp (9) in the inner cavity of the blank (6) having a tooth structure as a counter-mould; • - a drive for generating a relative movement in a feed direction (7) between the rollers (1) and the blank (6). The invention is characterized by the following features: • - a wedge-shaped intermediate body (11) is provided which presses the rollers (1) on the bearing journal (2) by exerting a pressure, stabilizes said intermediate body in a fixed environment, and the position of said intermediate body in the feed direction (7) is determined by at least one replaceable spacer.