Low Plasticity Burnishing: An Innovative Manufacturing Method for Biomedical Applications

2008 ◽  
Vol 130 (2) ◽  
Author(s):  
C. Y. Seemikeri ◽  
P. K. Brahmankar ◽  
S. B. Mahagaonkar
Keyword(s):  
Surface Roughness ◽  
Fatigue Life ◽  
Surface Integrity ◽  
Biomedical Applications ◽  
Hip Prosthesis ◽  
Surface Hardness ◽  
Surface Characteristics ◽  
Manufacturing Method ◽  
Work Material ◽  
Low Plasticity Burnishing

Biomedical manufacturing technologies are assuming highly visible position at the frontiers of manufacturing. A new field, “engineered surfaces,” is emerging as a more effective and economic route to successful manufacture. Low plasticity burnishing (LPB) is relatively a new method of surface enhancement, which raises the burnishing to the next level of sophistication. LPB can provide deep and stable surface compression for improved surface integrity characteristics. This technology could be applied to diversified biomedical applications, since it has the potential to improve many surface characteristics, such as low- and high-cycle fatigue strengths, surface finish, surface hardness, corrosion resistance, wear resistance, etc. The present study focuses on the surface roughness, microhardness, surface integrity, and fatigue life aspects of AISI 316L work material, which is most commonly used in prosthesis, using full factorial design of experiments. Favorable and optimum conditions could be predicted and tailored for different biomedical requirements and applications. The assessment of the surface integrity aspects on work material was done, in terms of identifying the predominant factors, their order of significance, evaluating the interaction effects of parameters, and setting the levels of the factors for minimizing surface roughness and∕or maximizing surface hardness and fatigue life. Regression models were developed for surface characteristics of importance as response variables. Subsurface microhardness studies were also done to assess the depth of compression, altered material zone, and correlate fatigue life with surface roughness and surface hardness. The process can be applied to critical components used in biomedical field, such as total hip prosthesis, invasive surgeries, or medical implants effectively, as the LPB process today has significant process cycle time advantages, lower capital cost, and adaptability to conventional machine shop environment.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Experimental Study on the Effect of Surface Integrity on Fatigue Performance of Aero-Engine Blades

2021 ◽  
Author(s):  
Yun Huang ◽  
Shaochuan Li ◽  
Guijian Xiao ◽  
Benqiang Chen ◽  
Yi He ◽  
...  
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Fatigue Life ◽  
Fatigue Strength ◽  
Fatigue Test ◽  
Surface Texture ◽  
Surface Characteristics ◽  
Service Performance ◽  
Aero Engine ◽  
Vibration Fatigue

Abstract As the core component of aero-engine, the service performance of aero-engine blade has an important influence on the engine’s reliability and safety performance. Existing studies have shown that machined surface characteristics affect the fatigue strength of components. However, current studies are all based on regular fatigue samples. The structure of blades different from fatigue samples, and the influence mechanism of structural differences on the service performance of blades is still unclear. In addition, the conventional fatigue test conditions are not representative for the blades’ actual service conditions, so it is difficult to realize the processing process for the service performance optimization. In this study, the aero-engine blades processed by abrasive belt grinding and the vibration fatigue test bench were used to explore the influence of surface roughness, surface texture, and surface residual stress on the fatigue performance of aero-engine blades under actual working conditions. The aero-engine blades were ground with different process parameters to obtain different single-factor surface characteristics. By comparing the vibration fatigue life of blades with different surface features, the influence degree of each surface feature on the fatigue life was explored. Results showed that surface roughness has the greatest influence on fatigue strength, followed by residual stress, and surface texture has the least influence on fatigue strength.

Surface Integrity of Biodegradable Magnesium-Calcium (Mg-Ca) Alloy by Low Plasticity Burnishing

2010 ◽  
Author(s):  
M. Salahshoor ◽  
Y. B. Guo
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Integrity ◽  
Bulk Material ◽  
Large Diameter ◽  
Biological Response ◽  
The Body ◽  
Low Plasticity Burnishing ◽  
Sever Plastic Deformation ◽  
Biodegradable Magnesium

When a device is implanted into the body, into either hard or soft tissue, the body will respond. While the bulk material of the device is often important for integrity and mechanical success, the device surface is at the interface with biology. Major effort has been spent modifying a biomaterial surface in order to elicit or inhibit a biological response. Metallic biodegradable Magnesium-Calcium (Mg-Ca) alloys have attracted an increased attention for orthopedic fixation applications. This research focuses on low plasticity burnishing (LPB) as a novel surface modification technique that is added to the surface to control biodegradation as a biological response. The effects of burnishing pressure as an important process parameter on surface integrity characteristics such as surface roughness, surface topography, and residual stresses are investigated. Burnished surface roughness is smaller than the machined ones. However, some amount of waviness is observed which might be due to large diameter of the burnishing ball and sever plastic deformation. High compressive residual stresses are measured on the burnished surface.

scholarly journals Rolling Contact Fatigue Life of Case−Hardened Steel Treated by Shot Peenings with Shot Diameters of 0.05 mm and 0.30 mm

2011 ◽  
Vol 86 ◽  
pp. 645-648 ◽  
Author(s):  
Lei Wang ◽  
Guang Liang Liu ◽  
Masanori Seki ◽  
Masahiro Fujii ◽  
Qian Li
Keyword(s):  
Surface Roughness ◽  
Fatigue Life ◽  
Shot Peening ◽  
Fine Particle ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Surface Hardness ◽  
Hardened Steel ◽  
Rolling Contact ◽  
Contact Fatigue Life

In order to investigate the influence of different shot peenings on the rolling contact fatigue life of case−hardened steel, the thrust type rolling contact fatigue test was performed with a ball−on−disk contact tester. In this study, the case−hardened steel disks were treated by the fine particle peening with a shot diameter of 0.05 mm and the normal shot peening with a shot diameter of 0.30 mm. The surface hardness and the surface compressive residual stress of the test disks were increased by these peenings. On the other hand, the surface roughness of the test disks was increased by the normal shot peening, and was decreased by the fine particle peening. The rolling contact fatigue test showed that the rolling contact fatigue life of the test disks was improved by the fine particle peening, and was not improved by the normal shot peening. The rolling contact fatigue life of the test disks became longer as their surface roughness became smaller. Therefore, it follows from this that the fine particle peening, which can provide the increase in surface hardness and the decrease in surface roughness, is good for the increase in the rolling contact fatigue life of case−hardened steel.

Magnetorheological finishing of copper cylindrical roller for its improved performance in printing machine

2020 ◽  
pp. 095440892094523
Author(s):  
Manpreet Singh ◽  
Anant Kumar Singh
Keyword(s):  
Surface Roughness ◽  
Surface Hardness ◽  
Ground Surface ◽  
Surface Characteristics ◽  
Fluid Composition ◽  
Finishing Process ◽  
Finished Surface ◽  
Measuring Machine ◽  
Mr Polishing Fluid ◽  
Cylindrical Roller

The copper cylindrical roller plays an important role in the printing operation. The copper roller requires fine and uniform finishing to uniformly distribute the colours and ingot material. Fine and uniform finishing of copper cylindrical rollers get difficulty using the traditional finishing processes due to their ductility and low hardness. Therefore, to achieve this fine finishing requirement, the rotary rectangular tool core-based magnetorheological (MR) finishing process is employed. Initially, the suitable MR polishing fluid composition is selected for the effective fine finishing of the surface of the copper cylindrical rollers. Furthermore, the central composite design is used to optimize the MR finishing process parameters. The surface roughness profiles, surface texture, and reflection tests are performed on the initial ground surface and the MR finished surface of the copper roller. The surface roughness value gets reduced from 190 nm to 25 nm after 4 hrs MR finishing with the optimum parametric conditions over the copper cylindrical roller surface having a dimension of 120 mm in length and 25 mm in diameter. The present MR finishing process found effective to significantly reduce the surface roughness value and enhance the surface characteristics of the copper cylindrical rollers. The geometrical dimensions in terms of circularity and straightness are also checked on the initial ground surface and finished surface of the copper cylindrical roller using the coordinate measuring machine and waviness test. The enhancement in surface characteristics, dimensional accuracy, and surface hardness after the present MR finishing process is found to be beneficial for improving the functional performance of the copper cylindrical rollers in the printing processing machine.

scholarly journals Optimization of parameters in cylindrical and surface grinding for improved surface finish

2018 ◽  
Vol 5 (5) ◽  
pp. 171906 ◽  
Author(s):  
Dinesh Kumar Patel ◽  
Deepam Goyal ◽  
B. S. Pabla
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Finish ◽  
Surface Characteristics ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cylindrical Grinding ◽  
Grinding Parameters ◽  
Wheel Material

Surface integrity has attracted the attention of researchers for improving the functional performance of engineering products. Improvement in surface finish, one of the important parameters in surface integrity, has been attempted by researchers through different processes. Grinding has been widely used for final machining of components requiring smooth surfaces coupled with precise tolerances. Proper selection of grinding wheel material and grade with grinding parameters can result in an improved surface finish and improved surface characteristics. The present work reports the study of the effect of grinding parameters on surface finish of EN8 steel. Experiments were performed on surface grinding and cylindrical grinding for optimization of grinding process parameters for improved surface finish. Grinding wheel speed, depth of cut, table feed, grinding wheel material and table travel speed for surface grinding operation, and work speed for cylindrical grinding operation were taken as the input parameters with four types of grinding wheels (Al 2 O 3 of grades K and L, and white alumina of grades J and K). The surface roughness was taken as an output parameter for experimentation. The grinding wheel material and grade have been observed to be the most significant variables for both cylindrical grinding and surface grinding. Surface roughness in the case of surface grinding is better compared to that of cylindrical grinding, which can be attributed to vibrations produced in the cylindrical grinding attachment. Surface roughness ( R a ) values of 0.757 µm in cylindrical grinding and 0.66 µm in surface grinding have been achieved.

Influence of thermal and pH cycles on surface characteristics lithium disilicate glass-ceramic dental crowns milled with CAD/CAM process

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Yajvinder Singh ◽  
Vishal Gulati
Keyword(s):  
Surface Roughness ◽  
Glass Ceramic ◽  
Research Work ◽  
Surface Hardness ◽  
Surface Characteristics ◽  
Lithium Disilicate ◽  
Content Type ◽  
Cad Cam ◽  
Group 3 ◽  
Group 2

Purpose The paper aims to evaluate the influence of thermo-chemical cycles of oral fluids on the surface attributes (roughness and microhardness) of lithium disilicate glass-ceramic (LDC) crown restorations manufactured with CAD/CAM technology. Design/methodology/approach There have been 24 LDC crowns manufactured using the CAD/CAM process for their respective preparation dies ply methyl methacrylate (PMMA) of mandibular left second premolar tooth (n = 8 each group). The standard procedure was used to glaze 16 crown samples (Groups 2 and 3).Samples of Group 3 were aged with thermal (563°C and 5563°C) and pH (2–14) cycles. All 24 samples were tested with a Profilometer and a Vicker hardness tester was used for their surface roughness and hardness measurement, respectively. Findings In statistical examination on SPSS Statistics 20 (IBM) software, of surface roughness values (Ra) and Vicker hardness values from different groups, Tukey HSD test was executed in one-way ANOVA (a = 0.05). The means Ra for groups were accordingly Group 3 > Group1 > Group 2 (p < 0.001). Similarly, micro-hardness was in order of Group 2 > Group 1 > Group 3 (p < 0.001). Research limitations/implications The research work does not have any limitations. Originality/value Surrounding temperature and pH significantly impact the surface characteristics of lithium disilicate crown restoration. The study also reveals the inverse relationship between surface roughness and surface hardness parameters. The observed results and facts revealed well in agreement with the past research studies.

scholarly journals Novel Zirconia Surface Treatments for Enhanced Osseointegration: Laboratory Characterization

2014 ◽  
Vol 2014 ◽  
pp. 1-8 ◽  
Author(s):  
Ola H. Ewais ◽  
Fayza Al Abbassy ◽  
Mona M. Ghoneim ◽  
Moustafa N. Aboushelib
Keyword(s):  
Surface Roughness ◽  
Atomic Force Microscopy ◽  
Surface Hardness ◽  
Surface Characteristics ◽  
Low Pressure ◽  
Surface Treatments ◽  
Control Surface ◽  
Force Microscopy ◽  
Atomic Force ◽  
Zirconia Implants

Purpose. The aim of this study was to evaluate three novel surface treatments intended to improve osseointegration of zirconia implants: selective infiltration etching treatment (SIE), fusion sputtering (FS), and low pressure particle abrasion (LPPA). The effects of surface treatments on roughness, topography, hardness, and porosity of implants were also assessed.Materials and Methods. 45 zirconia discs (19 mm in diameter × 3 mm in thickness) received 3 different surface treatments: selective infiltration etching, low pressure particle abrasion with 30 µm alumina, and fusion sputtering while nontreated surface served as control. Surface roughness was evaluated quantitatively using profilometery, porosity was evaluated using mercury prosimetry, and Vickers microhardness was used to assess surface hardness. Surface topography was analyzed using scanning and atomic force microscopy (α=0.05).Results. There were significant differences between all groups regarding surface roughness (F=1678,P<0.001), porosity (F=3278,P<0.001), and hardness (F=1106.158,P<0.001). Scanning and atomic force microscopy revealed a nanoporous surface characteristic of SIE, and FS resulted in the creation of surface microbeads, while LPPA resulted in limited abrasion of the surface.Conclusion. Within the limitations of the study, changes in surface characteristics and topography of zirconia implants have been observed after different surface treatment approaches. Thus possibilities for enhanced osseointegration could be additionally offered.

scholarly journals A Study on the Improvement of the Fatigue Life of Bearings by Ultrasonic Nanocrystal Surface Modification Technology

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1114 ◽  
Author(s):  
Shirmendagva Darisuren ◽  
Jeong-Hyeon Park ◽  
Young-Sik Pyun ◽  
Auezhan Amanov
Keyword(s):  
Surface Roughness ◽  
Surface Modification ◽  
Fatigue Life ◽  
Roller Bearing ◽  
Surface Hardness ◽  
Oil Lubrication ◽  
Roller Bearings ◽  
Before And After ◽  
Lubrication Conditions

In this study, the effects of ultrasonic nanocrystal surface modification (UNSM) technology on the fatigue life of needle roller bearings were investigated. The fatigue life of the untreated and UNSM-treated needle roller bearings was evaluated using a roller fatigue tester at various contact stress levels, under oil lubrication conditions. It was found that the fatigue life of the UNSM-treated needle roller bearing was extended by approximately 34.3% in comparison with the untreated one. The results of the surface roughness and surface hardness of the needle roller bearings before and after UNSM technology were compared and discussed in order to understand the role of UNSM technology in improving fatigue life. It was found that the application of UNSM technology to the needle roller bearings can improve their fatigue life by reducing the friction coefficient and increasing the wear resistance, which may be attributed to the reduction in surface roughness from 0.50 µm to 0.15 µm and also the increase in surface hardness from 58 HRC to 62 HRC.

scholarly journals Better Surface Integrity and Tribological Properties of Steel Sintered by Powder Metallurgy

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3172
Author(s):  
Tae-Hwan Lim ◽  
Chang-Soon Lee ◽  
In-Sik Cho ◽  
Auezhan Amanov
Keyword(s):  
Surface Roughness ◽  
Powder Metallurgy ◽  
Tribological Properties ◽  
Surface Integrity ◽  
Surface Hardness ◽  
Xrd Analysis ◽  
Treatment Temperature ◽  
Tribological Characteristics ◽  
Three Samples ◽  
Counter Surface

The current research reports the improvement in surface integrity and tribological characteristics of steel prepared using a powder metallurgy (PM) by ultrasonic nanocrystal surface modification (UNSM) at 25 and 300 °C. The surface integrity and tribological properties of three samples, namely, as-PM, UNSM-25 and UNSM-300 were investigated. The average surface roughness (Ra) of the as-PM, UNSM-25 and UNSM-300 samples was measured using a non-contact 3D scanner, where it was found to be 3.21, 1.14 and 0.74 µm, respectively. The top surface hardness was also measured in order to investigate the influence of UNSM treatment temperature on the hardness. The results revealed that the as-PM sample with a hardness of 109 HV was increased up to 165 and 237 HV, corresponding to a 32.1% and 57.2% after both the UNSM treatment at 25 and 300 °C, respectively. XRD analysis was also performed to confirm if any changes in chemistry and crystal size were took place after the UNSM treatment at 25 and 300 °C. In addition, dry tribological properties of the samples were investigated. The friction coefficient of the as-PM sample was 0.284, which was reduced up to 0.225 and 0.068 after UNSM treatment at 25 and 300 °C, respectively. The wear resistance was also enhanced by 33.2 and 52.9% after UNSM treatment at both 25 and 300 °C. Improvements in surface roughness, hardness and tribological properties was attributed to the elimination of big and deep porosities after UNSM treatment. Wear track of the samples and wear scar of the counter surface balls were investigated by SEM to reach a comprehensive discussion on wear mechanisms. Overall, it was confirmed that UNSM treatment at 25 and 300 °C had a beneficial effect on the surface integrity and tribological characteristics of sintered steel by the PM that is used in a shock absorber for a car engine.

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