Showing papers on "Roller burnishing published in 2021"

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Abstract: This paper deals with the optimization of external roller burnishing operation using a CNC lathe for a Mg-SiC metal matrix. Magnesium metal was alloyed with 10% (w/w) of SiC particles as a reinforcement. The Stir casting process was used to cast the bars. CNC turning was then performed on these bars to prepare them for the roller burnishing process. The process parameters considered during burnishing are speed, feed rate, force and number of tool passes. Surface roughness, microhardness and out of roundness were the outputs of each experiment. The Taguchi methodology was used to design an experiment. This design yielded an L16 (44) Matrix. Response Surface Methodology was then used for procuring the optimized set of process parameters. Surface plots were studied to understand the impact of all the potential combinations of the process parameters. Regression equations were formulated between the input and output parameters. The optimum surface roughness of 0.1506 μm, surface hardness of 57.9996 HV and out of roundness of 0.0151 mm were obtained from the following burnishing parameters: speed of171 rpm, feed rate of 0.18 mm/rev, force of 21 N and 3 passes. The optimized parameters were found with the desirability factor of 0.9991.

Optimization of the Internal Roller Burnishing Process for Energy Reduction and Surface Properties

Abstract: Improving the surface quality after burnishing operation has been the subject of various published investigations. Unfortunately, the trade-off analysis between the energy consumption and surface characteristics of the internal burnishing has been not addressed due to the expensive cost and huge efforts required. The objective of the present work is to optimize burnishing factors, including the spindle speed, burnishing feed, depth of penetration, and the number of rollers for minimizing the energy consumed in the burnishing time, as well as surface roughness and maximizing Rockwell hardness. An adaptive neuro-based-fuzzy inference system (ANFIS) was used to develop burnishing objectives in terms of machining parameters. The optimization outcomes were selected using an evolution algorithm, specifically the non-dominated sorting particle swarm optimization (NSPSO). The results of the proposed ANFIS models are significant and can be employed to predict response values in industrial applications. The optimization technique comprising the ANFIS and NOPSO is a powerful approach to model burnishing performances and select optimal parameters as compared to the trial and error method as well as operator experience. Finally, the optimal solution can help to achieve the improvements in the energy consumed by 16.3 %, surface roughness by 24.3 %, and Rockwell hardness by 4.0 %, as compared to the common values.

Finite element modelling of combined turning/burnishing effects on surface integrity of Ti6Al4V alloy

Abstract: This paper presents a physics-based model able to simulate the flow stress behavior of the Ti6Al4V alloy during subsequent severe plastic deformation processes, namely turning and burnishing. All the physical and metallurgical mechanisms that accommodate the deformation were considered to describe the material strengthening and they were implemented via user subroutine in a commercial finite element software. Then, the proposed numerical model was used to investigate the effect of combined turning/burnishing processes on the surface integrity of manufactured Ti6Al4V components. Turning and roller burnishing experiments were conducted to validate the proposed finite element model and to analyze the microstructural phenomena and the output variables. The implemented model well fits experimental results, precisely predicting the evolution of grain size, dislocations, hardness, and residual stresses. Different process combinations can lead to similar microstructures and information on different contributions can be highlighted through physics-based modelling and simulated process combinations.

Experimental and Numerical Analysis of the Depth of the Strengthened Layer on Shafts Resulting from Roller Burnishing with Roller Braking Moment.

Abstract: The article presents the results of investigations into the depth of the plastically deformed surface layer in the roller burnishing process. The investigation was carried out in order to obtain information on the dependence relationship between the depth of plastic deformation, the pressure on the roller and the braking torque. The research was carried out according to the original method developed by the authors, in which the depth of plastic deformation is increased by applying a braking torque to the burnishing roller. In this method, it is possible to significantly increase (up to 20%) the depth of plastic deformation of the surface layer. The tests were carried out on a specially designed device on which the braking torque can be set and the force of the rolling resistance of the roller during burnishing can be measured. The tests were carried out on specimens made of C45 heat-treatable carbon steel. The dependence of the depth of the plastically deformed surface layer was determined for a given pressure force and variable braking moments. The depth of the plastically deformed layer was measured on the deformed end face of the ring-shaped samples. The microhardness in the sample cross-section and the evolution of the microstructure were both analysed.

Improvement in Fatigue Performance of 2024-T3 Al Alloy Via Single Toroidal Roller Burnishing

Abstract: Mechanical surface treatment, based on static severe plastic deformation of the surface layer, is a cost-effective approach to improving surface integrity and thus the operating properties of metal components. The present work examines the possibility of using single toroidal roller burnishing (STRB) to implement the deep rolling concept. The effect of the STRB process parameters on the fatigue behavior of 2024-T3 Al alloy specimens is investigated. The specimens were manufactured using a newly developed STRB device. The conventional fatigue limit of 2024-T3 Al alloy is established using the S–N curve approach and tangent method. The STRB implementation as the deep rolling process for 2024-T3 Al alloy specimens provides a maximum conventional fatigue limit of 256 MPa. Compared to the reference condition, the fatigue limit has increased by 38.4%. Calculated at the number of cycles corresponding to the conventional fatigue limit, the fatigue life is enhanced more than 2000 times over. The increase in the number of passes enhances the fatigue strength: as a result the conventional fatigue limit of the treated 2024-T3 Al alloy increased. Increasing the number of passes has practical meaning for up to six passes, after which the effect is negligible.

Multi-performance optimization of multi-roller burnishing process in sustainable lubrication condition

Abstract: Sustainable machining processes are efficiently achieved using the selection of optimal parameters. In this study, the minimum quantity lubrication-assisted multi-roller burnishing (MQLAMRB) operat...

Effect of burnishing on Inconel 718 workpiece surface heated by infrared radiation

Abstract: Roller burnishing process is a post-machining surface finishing technique that has an advantage over other finishing processes, such as shot blasting or abrasive-tooling processes, because of its s...

Multi-response performance optimization of burnishing operation for improving hole quality

Abstract: Improving hole quality in the burnishing operation is a necessary demand to enhance its applications in different industrial aspects. The purpose of this investigation is to optimize process parameters, including the burnishing speed (Vs), depth of penetration (dp), and feed rate (Vf) for decreasing cylindricity (CL), circularity (CC), dimensional deviation (DD), and burnishing roughness (BR) under the minimum quantity lubrication (MQL). Firstly, the working principle of the MQL-based internal roller burnishing (MBIRB) operation has been proposed. A set of burnishing trials is performed using the Taguchi design of experiment. The gray relational analysis (GRA) is utilized to compute the weight value of each response, while the combined compromise solution (CCS) is employed to set the best optimal solution. Moreover, empirical models of technological performances are proposed regarding process parameters with the aid of the response surface method (RSM). The results indicated that the optimal outcomes of the Vs, dp, and Vf were 600 rpm, 0.06 mm, and 100 mm/min, respectively, while the CL, CC, DD, and BR were decreased 80.8, 2.1, 48.0, and 54.4%, respectively, as compared to the worst case. The CL, CC, and BR were reduced by 88.3, 60.0, and 93.4%, respectively, in comparison with the pre-machined characteristics. Furthermore, the predictive models of the burnishing responses could be utilized in the burnishing operation to predict the performance values with the cost-effectiveness and less manufacturing damage.

On the Effects of Burnishing Process on Tribological Surface Resistance of Additively Manufactured Steel

Abstract: Burnishing is a Severe Plastic Deformation process having the potential to replace expensive finishing post processes. It is considered a super finishing process due to its results in terms of drastic roughness reduction. Also, additional advantages include the surface integrity improvement functionalized to the specific application. Even though burnishing is widely applied for surface improvement of conventional materials, knowledge about its effect on additively manufactured metals is still limited. This paper aims to fill this gap presenting experiments on roller burnishing on additively manufactured stainless steel in order to improve its tribological performance. The experimental campaign was carried out to find suitable process parameters able to drastically improve the tribological behavior of the final product. In particular, the influence of the burnishing forces on the whole surface quality has been addressed. The overall results demonstrate that the selected burnishing configuration is able to successfully modify the surface characteristics of the steel, making it appropriate for critical applications. Furthermore, the experimental findings allow to conclude that burnishing process can replace a series of post processes needed after additive manufacturing, drastically reducing the time and costs associated to the manufacturing process and meeting Industry 4.0 requirements.

Finite element and experimental study of the residual stresses in 2024-T3 Al alloy treated via single toroidal roller burnishing

Abstract: This article presents the outcomes of finite element (FE) simulations and X-ray stress measurements of residual stresses in high-strength 2024-T3 Al alloy introduced via the single toroidal roller burnishing (STRB) process. In terms of the deforming toroidal roller geometry, STRB is particularly suitable for deep rolling. A 3D FE model was developed using the flow stress concept, and the actual STRB kinematics was simulated to evaluate both hoop and axial residual stresses. The FE model was validated through a comparison of FE and X-ray residual stress distributions. The effects of the burnishing force, feed rate, and number of passes on the residual hoop and axial stresses were studied. It was established that increasing the feed rate leads to a decrease in the residual hoop stresses and an increase in the residual axial stresses. The greater burnishing force increases the compressive zone depth and only slightly increases the surface residual stresses. The FE and X-ray stress analyses confirm the effectiveness of STRB of 2024-T3 Al alloy to introduce significant residual compressive axial and hoop stresses.

Surface Modifications Induced by Roller Burnishing of Ti6Al4V Under Different Cooling/Lubrication Conditions

Abstract: The paper presents a deep analysis of surface modifications induced by roller burnishing process of Ti6Al4V titanium alloy. The extensive experimental campaign has been performed based on a Design of Experiments at varying lubrication/cooling strategies (dry, cryogenic and MQL), roller radius, burnishing speed and burnishing depth. The resulting surface integrity has been analyzed in terms of surface roughness, micro hard-ness, microstructural changes and tribological performance. In particular, the wear rate of the burnished sample has been evaluated as a quality indicator of the process. The overall results show the influence of burnishing process parameters on surface quality and wear resistance of Ti6Al4V highlighting the capability of the process to significantly improve the above performance especially when cryogenic cooling is applied. Finally, the extensive experimental activity allowed to find a combination of processing parameters and lubrication conditions able to significantly improve the surface quality of the final component.

Butterfly Optimization Algorithm for Optimization of Roller Burnishing Process Parameters

Abstract: In this work, an attempt is made to optimize the roller burnishing process parameters using a novel butterfly optimization algorithm. A total of 17 experiments were conducted according to Box–Behnken design considering three process parameters, namely burnishing speed, burnishing feed, burnishing depth to achieve higher surface hardness value. Single-objective optimization is performed using a nature-inspired butterfly optimization algorithm in which objective function is developed using RSM to select the optimal setting of burnishing process parameters. A comparison of the experimental and optimization results for surface hardness shows that the percentage error lies ±2%.

Hybrid Processes with Controlled Mechanisms

Abstract: In the second CIRP group (II) some hybrid processes with controlled application of their individual mechanisms are selected (Sect. 1.3). They cover two subtractive and transformative processes (as for instance grind-hardening or sequential cutting and sliding/roller burnishing) or two transformative processes (as for instance cryogenic deep rolling when the machining zone is cryogenically cooled by CO2 snow).

Optimization of Roller Burnishing Parameters of Al(SiC)p Metal Matrix Composite with TiAlN-Coated Roller Using Response Surface Methodology

Abstract: In this paper, the optimization of roller burnishing parameters of silicon carbide particles-reinforced aluminum composites of metal matrix base using response surface methodology (RSM) was carried out. For the burnishing roller material, tungsten carbide was coated with TiAlN using physical vapor deposition (PVD) technique. Experiments were conducted in dry condition by changing speed of the burnishing tool and number of passes. The input parameters were changed at different levels in order to evaluate its influence on output responses such as roughness and hardness of the surface. The optimization was carried out using response surface methodology.