Roller burnishing

About: Roller burnishing is a research topic. Over the lifetime, 395 publications have been published within this topic receiving 3322 citations.

Improved Method Being Developed for Surface Enhancement of Metallic Materials

Abstract: Surface enhancement methods induce a layer of beneficial residual compressive stress to improve the impact (FOD) resistance and fatigue life of metallic materials. A traditional method of surface enhancement often used is shot peening, in which small steel spheres are repeatedly impinged on metallic surfaces. Shot peening is inexpensive and widely used, but the plastic deformation of 20 to 40 percent imparted by the impacts can be harmful. This plastic deformation can damage the microstructure, severely limiting the ductility and durability of the material near the surface. It has also been shown to promote accelerated relaxation of the beneficial compressive residual stresses at elevated temperatures. Low-plasticity burnishing (LPB) is being developed as an improved method for the surface enhancement of metallic materials. LPB is being investigated as a rapid, inexpensive surface enhancement method under NASA Small Business Innovation Research contracts NAS3-98034 and NAS3-99116, with supporting characterization work at NASA. Previously, roller burnishing had been employed to refine surface finish. This concept was adopted and then optimized as a means of producing a layer of compressive stress of high magnitude and depth, with minimal plastic deformation (ref. 1). A simplified diagram of the developed process is given in the following figure. A single pass of a smooth, free-rolling spherical ball under a normal force deforms the surface of the material in tension, creating a compressive layer of residual stress. The ball is supported in a fluid with sufficient pressure to lift the ball off the surface of the retaining spherical socket. The ball is only in mechanical contact with the surface of the material being burnished and is free to roll on the surface. This apparatus is designed to be mounted in the conventional lathes and vertical mills currently used to machine parts. The process has been successfully applied to nickel-base superalloys by a team from the NASA Glenn Research Center, Lambda Research, and METCUT Research, as supported by the NASA Small Business Innovation Research Phase I and II programs, the Ultra Safe program, and the Ultra- Efficient Engine Technology (UEET) Program.

Design and Fabrication of New Type of Dynamometer to Measure Radial Component of Cutting force and Experimental Investigation of Optimum Burnishing force in Roller Burnishing Process

Abstract: In this work, an attempt has been made to design and fabricate a new type of dynamometer to measure radial component of cutting force using strain gauges Dynamometer is required to measure the components of cutting force in any metal cutting process The dynamometer has been calibrated and tested for performance It is used in roller burnishing experiment on aluminum work piece under various conditions In roller burnishing, a hard roller is pressed against a rotating cylindrical work piece and parallel to the axis of the work piece on lathe Optimum values of burnishing force and the corresponding surface roughness value (R a ) are obtained for different lubricant applications in roller burnishing operation This dynamometer can be manufactured at a low cost and it can be used for tests on lathe in metal cutting laboratories and engineering colleges

Effect of roller burnishing process on tool steel material using cnc lathe

Abstract: Roller burnishing is a technique used to super finish various components. In this technique, the type of contact between the workpiece and the tool is a line. The worpiece rotates on the chuck and the tool is held perpendicular to the length of the workpiece. Plastic deformation of the work piece surface occurs giving rise to a new topography. The effect of various operating parameters such as burnishing force, speed, feed, roller width, and number of pass are investigated for better surface finish. Workpeice material is HCHCr tool steel (35 HRC) and the burnishing tool material is tungsten carbide (69 HRC). The minimum surface roughness obtained was 0.122 µm and the maximum micro hardness was 589 HV.

The Effect of Roller Burnishing on Surface Hardness and Roughness of Aluminum Alloy

Abstract: Burnishing is a chip less machining process in which a rotating roller or ball is pressed against a metal piece. It is a cold working process and involves plastic deformation to the surface irregularities. Simple roller-burnishing tool was used for the experimental work of the present study. Surface texture and micro hardness tests, were applied to demonstrate the effects of the burnishing force and feed rates on the surface roughness and surface hardness of commercially available aluminum. A detailed experimental program was used in this study where specimens were subjected to different levels of feeding speed and burnishing force. The roughness and micro hardness were measured at the end of each burnishing combination of feeding speed and burnishing force. Significant enhancement in the surface roughness values were clearly observed, meanwhile, very little enhancement to the surface hardness were encountered. The best results were obtained at the lowest value of the burnishing feed rate and maximum burnishing force used in this investigation.