Showing papers on "Roller burnishing published in 2020"
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TL;DR: Results show that the technique greatly improves surface roughness, and eliminates the kinematic-driven roughness pattern of turning, leading to a more isotropic finishing.
Abstract: Roller burnishing technique to achieve isotropic surface topography on cylindrical components made of austempered ductile iron (ADI) casting is presented in this paper. In the last years, ADI casting components are used in many mechanical applications, due to their enhanced mechanical properties. ADI castings are difficult-to-cut materials; therefore, advanced techniques to improve manufacturing productivity are necessary and under research. On the other hand, spiral roughness pattern produced by turning operation is a common source of unconformities in several applications. Turning produces a defined kinematic pattern, similar to a thread. This work presents a theoretical and experimental validation using different burnishing conditions. Roughness and surface topography and surface integrity were checked. Results show that the technique greatly improves surface roughness, and eliminates the kinematic-driven roughness pattern of turning, leading to a more isotropic finishing. A comparison between roller burnishing and ball burnishing is also presented in this paper.
28 citations
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TL;DR: In this paper, a deep experimental study on surface modifications induced by roller burnishing process of Ti6Al4V titanium alloy has been performed based on a design of experiments at varying lubrication/cooling strategies, roller geometry, coating, and burnishing speed.
Abstract: The paper presents a deep experimental study on surface modifications induced by roller burnishing process of Ti6Al4V titanium alloy. The experimental campaign has been performed based on a design of experiments at varying lubrication/cooling strategies, roller geometry, coating, and burnishing speed. The overall surface integrity has been analyzed in terms of surface roughness, micro hardness, topography, microstructural changes, and tribological performance. The results allowed to better define the relationships within burnishing process parameters and the surface quality of the final component. In particular, the obtained evidences show that cryogenic cooling conditions and coating tools significantly improve the hardness of the final component while the MQL lubrication leads to superior surface roughness. Overall, the process always improves the wear resistance of the components with optimal results when cryogenic cooling and coated tools are employed. Thus, the outcomes of the extensive experimental campaign allow to define a combination of process parameters leading to improved Ti6Al4V surface quality.
24 citations
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TL;DR: In this paper, the authors presented an efficient optimization to simultaneously decrease energy consumption as well as the mean roughness depth and improve the Brinell hardness for the burnished surface of H13 steel.
23 citations
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TL;DR: In this paper, a set of self-fabricated ultrasonic burnishing equipment was used to strengthen the surface of TC11 titanium alloy material by using a roller tip with or without heat treatment.
Abstract: A roller tip was utilized in a set of self-fabricated ultrasonic burnishing equipment. Ultrasonic roller burnishing with/without heat treatment was proposed and investigated in the surface strengthening of TC11 titanium alloy material. Experimental research together with finite element analysis were carried out to perform the study. Three treatments, including conventional turning, ultrasonic roller burnishing at ambient temperature (URB) and ultrasonic roller burnishing at medium temperature (URB/HT), were comparatively evaluated in term of surface integrity and corrosion resistance of the treated sample. As a result, compared with URB, the surface of TC11 alloy treated by URB/HT had better surface finishing, which significantly improved corrosion resistance, and thus the surface of TC11 alloy was strengthened. The good performance of URB/HT was attributed to the combined effect of the high frequency dynamic impact from URB and the thermoplastic effect of the heat treatment. Owing to the excitation of the ultrasonic vibration during URB, an oscillating stress wave formed and propagated deep inside the being treated material, and the heat treatment in URB/HT case was supposed to accelerate this sort of stress propagation. Meanwhile, both the heat treatment and the dynamic oscillating stress wave facilitated the deformation of the surface layer.
23 citations
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TL;DR: In this article, the kinematic mechanism for plastic flow during surface generation in hybrid rotary ultrasonic burnishing Ti-6Al-4V with cylindrical roller tool was revealed.
Abstract: A hybrid machining technology with rotary ultrasonic roller burnishing process has been developed. There is no material removal when the machined surface is generated by the hybrid ultrasonic burnishing as comparing with other conventional cutting processes. The kinematic mechanism for plastic flow during surface generation in hybrid rotary ultrasonic burnishing Ti-6Al-4V with cylindrical roller tool was revealed in this paper. Firstly, the machining experiments were carried out for surface generation with hybrid rotary ultrasonic burnishing Ti-6Al-4V. Then, the experimental analysis was conducted and it showed that, there was little change in dimension of the rotary ultrasonic roller burnished workpiece compared to that of milled workpiece. Finally, a 3D finite element (FE) model was proposed to simulate the surface generation in hybrid rotary ultrasonic roller burnishing process. Three machining zones including pile-up deformation area, tensile deformation area, and compressive deformation area were selected for the analysis of the material plastic flow. It was found that the surface generated by rotary ultrasonic burnishing was mainly attributed to the plastic flow of material in these three deformation zones. The FE simulation results showed good agreements with the experimental ones. The proposed research results are helpful for the analysis and diagnosis of the surface generation in ultrasonic burnishing process.
17 citations
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TL;DR: In this article, a strategy to control the surface characteristics of additively manufactured stainless steel by roller burnishing is presented, in particular, process parameters have been carefully selected to improve the surface integrity of the worked material.
14 citations
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TL;DR: In this article, various rotary ultrasonic roller burnishing experiments were conducted to investigate the ultrasonic-induced phase redistribution of Ti-6Al-4V at different ultrasonic powers.
Abstract: Ultrasonic energy can promote the dislocation motion in ultrasonic-assisted machining. The phase redistribution of Ti-6Al-4V alloy will occur in ultrasonic-assisted machining with appropriate ultrasonic powers. The variations of the volume fractions of β-Ti and α-Ti influence the microhardness on the processed surface. In the present paper, various rotary ultrasonic roller burnishing experiments were conducted to investigate the ultrasonic-induced phase redistribution of Ti-6Al-4V at different ultrasonic powers. The volume fractions of β-Ti and α-Ti were measured by X-ray diffraction. SEM images of the processed surfaces were used to analyze the microstructure evolution and grain refinement of Ti-6Al-4V at various ultrasonic powers. Then, the distributions of local misorientation, texture and grain boundary were observed by EBSD. The results indicated that the microhardness approached the maximum value on the processed surface while the volume fraction of β-Ti reached its maximum value. Finally, the modified phenomenological model was applied to elucidate the relationship among the microhardness, the phase volume fractions and the grain refinement. The fitting degree for microhardness between the modified phenomenological model prediction and experimental measurement was 92.2 pct.
11 citations
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TL;DR: In this article, the principal component analysis and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) was used to explore the weight values of burnishing performances and select the optimum parameters.
Abstract: In the current work, the optimal factors are selected to achieve the improvements in the energy consumption (EB), power factor (PB), decreased roughness (DR) and improved surface hardness (IH) for the roller burnishing operation. The process inputs are the burnishing speed (V), the feed (f), and the depth (d). A hybrid approach comprising the principal component analysis and Technique for Order of Preference by Similarity to Ideal Solution was used to explore the weight values of burnishing performances and select the optimum parameters. Moreover, another optimization technique employing the response surface method and archive-based micro-genetic algorithm was adopted to identify the optimal outcomes in the continuous domain. The main findings showed the performances measured are primarily affected by the burnishing feed, depth and speed, respectively. The energy consumption and roughness are approximately decreased by 31.46% and 7.41%, while the power factor and hardness are improved by 17.47% and 43.09%, respectively, as compared to the general process. The outcomes and findings of the investigated work can be used for further research in sustainable design and manufacturing as well as directly used in the knowledge-based and expert systems for burnishing applications in industrial practices.
10 citations
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TL;DR: AISI 304L stainless steel in austenitized and in solution nitrided condition was severely mechanically deformed by surface roller burnishing, leading to a depth-gradient in the austenite stability as mentioned in this paper.
9 citations
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TL;DR: In this article, a ball and deep roller burnishing surface treatment device was developed to investigate the surface integral properties like residual stress, surface roughness and hardness of aluminium 2024 alloy before and after burnishing treatment process.
9 citations
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TL;DR: In this article, a comparative analysis involving three static burnishing processes: slide burnishing (SB), roller burnishing, and deep rolling (DR) is presented, and it is shown that three-quarters of the external work in SB converts into heat in the deforming element-workpiece contact area, which leads to the so-called softening effect in the surface layers.
Abstract: This article presents outcomes from a comparative analysis involving three static burnishing processes: slide burnishing (SB), roller burnishing (RB), and deep rolling (DR). The treated material was 41Cr4 steel. The investigative methods used were fully coupled thermal-stress finite element (FE) simulations and natural experiments. Using one and the same magnitudes for the governing factors, the basic difference among the compared processes was the type of contact between the deforming element and the surface being burnished—sliding friction for SB and rolling contact for RB and DR. SB was implemented with a spherical-ended polycrystalline diamond whereas RB and DR were conducted using a single toroidal roller with the same magnitude for the radius of the toroid surface as that for the radius of the deforming diamond. The objects of comparison were in themselves processes and considered to be alterations in the thermodynamic systems’ states, as were the obtained surface integrities (SIs) of the treated specimens and their fatigue behaviors. It was established that three-quarters of the external work in SB converts into heat in the “deforming element–workpiece” contact area, which leads to the so-called softening effect in the surface layers. The comparison of the energy balances of the investigated processes clearly demonstrates the thermo-mechanical nature of the SB process, whereas the deforming processes in the RB and DR can be assumed to be purely mechanical. On the other hand, SB provides less roughness, significantly greater micro-hardness, larger-in-absolute-values compressive residual stresses, a more refined microstructure and, as a result, greater fatigue strength compared with RB and DR.
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14 Dec 2020
TL;DR: In this article, a deep analysis of the burnishing parameters and their influence on the surface integrity of Ti-6Al-4V was presented, starting from a large experimental campaign.
Abstract: Burnishing is considered a super finishing process able to drastically increase surface quality in terms of hardness and roughness of the manufactured parts. Consequently, it is considered appealing for the performance enhancement of products where the surface quality plays a crucial role. However, when burnishing grade 5 titanium alloy, a quantitative relationship between process parameters and surface integrity is still missing. This work provides a deep analysis of the burnishing parameters and their influence on the surface integrity of Ti-6Al-4V. In particular, starting from a large experimental campaign, statistical analysis of the results is performed and models able to describe the surface integrity response based on different burnishing parameters are presented. The overall results allow us to clearly define the relationship within the input and output variables identifying, by the proposed models, different operational windows for surface integrity improvement.
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TL;DR: Based on a comprehensive experimental study, single toroidal roller burnishing (STRB) of the 2024-T3 Al alloy can be successfully implemented as a mixed burnishing process.
Abstract: Based on a comprehensive experimental study, single toroidal roller burnishing (STRB) of the 2024-T3 Al alloy can be successfully implemented as a mixed burnishing process. Optimum values of various governing factors provided minimum roughness and significant enhancement of the fatigue life of the treated specimens. With a planned experiment, regression analysis, and optimization procedure based on a genetic algorithm, the optimum factor values were established under a minimum roughness criterion. The derived model predicted a minimum roughness Ra = 0.074 μm. The experiment with optimal process parameters provided an average roughness (Ra) of 0.01 μm. STRB under these optimal conditions yields a relatively homogeneous surface in terms of microhardness with a surface microhardness increase coefficient of 37.6%. The parametric study of the residual surface hoop and axial stresses conducted via X-ray stress analysis shows that the STRB with near-optimal process parameters introduces significant residual stresses. STRB of the 2024-T3 Al alloy, implemented as a mixed burnishing process, produces a mirror-finish surface, improves the fatigue life by more than 2000 times, and increases the conventional fatigue limit by 35.1% compared to the reference condition.
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TL;DR: AISI 304L stainless steel in austenitized and in solution nitrided condition was severely mechanically deformed by surface roller burnishing, leading to a depth-gradient in the austenite stability as discussed by the authors.
Abstract: AISI 304L stainless steel in austenitized and in solution nitrided condition was severely mechanically deformed by surface roller burnishing. High-temperature solution nitriding was applied to achieve a nitrogen-concentration depth profile, leading to a depth-gradient in the austenite stability. X-ray diffraction, electron microscopy and hardness indentation were applied for characterization of the graded microstructures obtained by combining a composition profile and a deformation profile. While severe plastic surface straining of an austenitized specimen leads to a deformation-induced transformation of austenite into martensite, the solution nitrided specimen remains austenitic upon deformation, even in the region where nanocrystallization occurs. The deformation mechanisms operable in the nitrogen-stabilized austenitic stainless steel, i.e. twinning or dislocation glide, depend on the combination of applied plastic strain/strain rate, and the nitrogen-concentration dependent stacking fault energy.
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TL;DR: In this article, a 3D finite element model was built up to simulate the burnishing process and the predicted surface integrity parameters including subsurface deformation and residual stress were compared with the experimental measurements.
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TL;DR: In this article, a rotary ultrasonic burnishing of titanium alloy Ti-6Al-4V, whose surface had been machined with the face milling process, was proposed.
Abstract:
Ultrasonic burnishing is usually applied to make machined surface modification. The acoustic softening effect caused by ultrasonic vibration is beneficial to the machining of difficult-to-cut materials. In the present work, a burnishing force prediction model was proposed for rotary ultrasonic burnishing of titanium alloy Ti–6Al–4V, whose surface had been machined with the face milling process. Firstly, the contact between the burnishing roller and one single milling mark was analyzed with plane strain assumption based on the Boussinesq–Flamant contact problem. Then, the effect of ultrasonic softening on the yield stress of Ti–6Al–4V was investigated. The critical contact width and contact load that the burnishing roller crushed on one single milling mark were examined to confirm the feasibility of the proposed ultrasonic burnishing force prediction model. The experimental verifications were carried out at various ultrasonic powers. The burnishing forces from experiment measurements were consistent with the calculated results from the proposed model. The mean deviations between theoretical and experimental results of the ultrasonic burnishing force were 10.4%, 12.2%, and 15.2%, corresponding to the ultrasonic power at the level of 41 W, 158 W, and 354 W, respectively.
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13 Feb 2020TL;DR: An ultrasonic roller burnishing system comprises a roller and a controller as discussed by the authors, which is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure.
Abstract: An ultrasonic roller burnishing system comprises a roller and a controller. The roller is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure. The roller is pressed and rolled by a motion unit which is driven by a drive motor. The vibrating of the roller is driven by an ultrasonic vibration unit with an input current inputted thereinto. The controller is configured to adjust at least one of the pressing depth, the back pressure, the input current and the feed rate based on an expected residual compressive stress and a real time output power of the drive motor, to generate a residual compressive stress in the workpiece which is in an expected range predetermined based on the expected residual compressive stress.
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02 Sep 2020
TL;DR: In this article, the nano-drone burnishing process was performed on the surface of Al7175-T74 specimens and the results showed that the minimum surface roughness and maximum microhardness values can be reached in nano and dry roller burnishing processes at the penetration depth of 0.4 mm.
Abstract: The burnishing process is one of the non-removal finishing processes, which is employed to enhance surface quality, corrosion property, and surface microhardness. In this study, the dry burnishing process was performed on the surface of Al7175-T74 specimens. Furthermore, nanofluid containing alumina/graphene nanocomposite was employed to perform the Nano burnishing process on the same specimens. The results show that the arithmetic surface roughness parameter in nanofluid burnished samples is decreased by approximately 0.277 μm, 0.233 μm, and 0.345 μm for the penetration depths of 0.2, 0.3, and 0.4mm comparing to those of dry burnishing process. Moreover, microhardness values in Nano and dry burnishing processes are directly related to the penetration depth parameter. The results reveal that the values of microhardness for the nanofluid burnished samples with four penetration depths of 0.2, 0.3, 0.4, and 0.5 mm are increased about 3, 28, 42, and 39 Vickers comparing to those values of dry burnishing process. The results prove that the minimum surface roughness and maximum microhardness values can be reached in Nano and dry roller burnishing processes at the penetration depth of 0.4 mm. Eventually, analyzing elements distribution on the surface of burnished aluminum alloy specimens confirm that the alumina/graphene nanocomposite embedded in the burnished surfaces during Nano burnishing process.
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TL;DR: The main objective of the work is to develop adequate methods and mathematical models to enable the design of the macro-asperities of the surface burnishing process to maintain the dimensional tolerance of the shaped parts.
Abstract: The paper presents preliminary studies of a new innovative surface treatment method-the process of roller burnishing of macro-irregularities of the surface. As part of the work, the possibility of plastic shaping of the surface macrostructure with indentations (plateau structure), which will show anti-wear properties through appropriate surface shaping and the compressive stress state in the product's top layer, was investigated. The essence of the paper is the analysis of one of the aspects of the application of this processing method, i.e., the influence of the elastic recovery of the product on its technological quality measured by dimensional deviation. The main objective of the work is to develop adequate methods and mathematical models to enable the design of the macro-asperities of the surface burnishing process to maintain the dimensional tolerance of the shaped parts. The results of dependencies of elastic recovery of the asperities and the deviation of height, Δht, for sample depths of burnishing were presented. The model tests of the elastic recovery of the model material using the visioplasticity method show that with the increase of the value of the vertical surface asperities, the value of the elastic recovery of the material decreases. The increase of the deviation of the asperities' height causes a decrease in the value of elastic recovery. With the increase of the value of the vertical angle of the surface roughness, the value of the elastic recovery of the material is smaller.
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08 May 2020
TL;DR: In this article, a roller burnishing method for surface roughness of a ball head of an oil pump shaft was proposed, which reduced the probability of scratches and bumps caused by traditional methods.
Abstract: The invention provides a roller burnishing method for surface roughness of a ball head of an oil pump shaft. The roller burnishing method comprises the following steps of: step one. adding a brown aluminum oxide ball abrasive with the diameter of 12, a first brightener and first roll polishing liquid to a first vibrating burnisher; putting a workpiece, wherein the roll polishing time is 17-18 hours, and the rotation speed of the abrasive is 4-6 revolutions/min; and step two. adding a turmeric abrasive with the diameter of 5, a turmeric abrasive with the diameter of 6, a white high-alumina porcelain abrasive with the diameter of 8 and a white high-alumina porcelain abrasive with the diameter of 10 to a second vibrating burnisher, wherein the mass fractions of the four abrasives are 10 parts, 10 parts, 20-30 parts, and 20 parts in sequence; adding a second brightener and second roll polishing liquid; and putting the workpiece, wherein the roll polishing time 2.5 to 3 hours, and the rotation speed of the abrasives is 4-6 revolutions/min. The roller burnishing method can realize the batch processing and improve the efficiency. The outer diameter, knurling, roughness and other technicalparameters of the oil pump shaft can be effectively controlled. The probability of scratches and bumps caused by traditional methods is reduced. The roughness Rz value is greatly reduced; and the technical parameters of the workpiece are improved.
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21 Apr 2020
TL;DR: In this paper, the authors describe a roller burnishing tool with a base body extending along a longitudinal center axis, at least one roller holder 14 arranged radially adjustably on the base body, which holds a roller 15 rotatably.
Abstract: The invention relates to a roller burnishing tool 10 with a base body 12 extending along a longitudinal center axis 11, at least one roller holder 14 arranged radially adjustably on the base body 12, which holds a roller 15 rotatably, and an adjusting device 16 arranged in the base body 12 for adjusting the roller holder 14 cooperates in the radial direction with the roller holder 14. According to the invention, the roller holder 14 has a holder arm 18b holding the roller 15, which can be pivoted out in a radial direction by the adjusting device 16 relative to the base body 12 in a radial direction.
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12 Nov 2020
TL;DR: In this article, the authors describe a roller burnishing tool for treating a workpiece surface, comprising a base body (12) having at least one roller holder (2) which is arranged in a radially adjustable manner, wherein a burnishing roller (3) is arranged on each roller holder in a rotationally movable manner, and each roller has an external surface with a rough working section (4) having a predetermined roughness depth.
Abstract: The invention relates to a roller burnishing tool (1) for treating a workpiece surface, comprising a base body (12) having at least one roller holder (2) which is arranged in a radially adjustable manner, wherein a burnishing roller (3) is arranged on each roller holder (2) in a rotationally movable manner, and wherein at least one burnishing roller (3) has an external surface with a rough working section (4) having a predetermined roughness depth.
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15 Apr 2020
TL;DR: In this article, the authors described a roller burnishing tool with a cylindrical shape and a contact surface for coming into contact with the workpiece, and mounted such that it can be moved in a radial direction.
Abstract: The invention relates to a roller burnishing tool (10) having a roller support (12) which projects in an advancement direction (V) and on which, in a circumferential direction, at least one burnishing roller (14) for machining a workpiece surface is provided such that it can rotate about a roller axis (A), wherein the at least one burnishing roller (14) has a contact surface for coming into contact with the workpiece According to the invention, the at least one burnishing roller (14) has a basic cylindrical shape and the at least one burnishing roller (14) is mounted such that it can be moved in a radial direction (R)
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31 Mar 2020
TL;DR: In this article, the surface of the wheel is strengthened by adding a wheel surface treatment process so as to obtain a forged aluminum alloy wheel with long service life, wear resistance, corrosion resistance and oxidation resistance.
Abstract: The invention relates to the technical field of aluminum alloy wheels, and particularly relates to a manufacturing method of a long-service-life forged aluminum alloy wheel The manufacturing method is characterized in that the surface of the wheel is strengthened by adding a wheel surface treatment process so as to obtain a forged aluminum alloy wheel with long service life, wear resistance, corrosion resistance and oxidation resistance The manufacturing method comprises the operation steps of S1, bar heating; S2, forging, specifically, conducting single-step forging on the heated bar; S3, punching and flaring, specifically, expanding rim legs by a certain angle, and punching the center of a forging stock at the same time; S4, cleaning and cooling, specifically, putting the forging stockinto a cleaning line for cleaning; S5, spinning, specifically, placing the forging stock on a spinning lower die for compaction; S6, heat treatment, specifically, conducting heat treatment by means of solid solution, quenching and artificial aging; S7, rough turning; S8, surface roller burnishing, specifically, conducting full roller burnishing on the front surface, a back cavity and an outer side rim of the wheel; S9, drilling and window milling; S10, surface wiredrawing, specifically, conducting wiredrawing treatment is conducted on the front surface and the back cavity of the wheel; and S11, surface passivation, specifically, putting the wheel into a passivation solution for soaking, washing with pure water after passivation and then drying