scholarly journals Numerical Simulation and Experimental Validation of Surface Roughness by the Smoothing Small Ball-Burnishing Process

Machines ◽  
2021 ◽  
Vol 9 (3) ◽  
pp. 48
Author(s):  
Quoc-Nguyen Banh ◽  
Hai-Dang Nguyen ◽  
Anh Son Tran
Keyword(s):  
Surface Roughness ◽  
Experimental Validation ◽  
Ball Burnishing ◽  
Small Ball ◽  
Workpiece Surface ◽  
Optimal Value ◽  
Experimental Surface ◽  
Burnishing Process ◽  
Simulated Surface ◽  
Plastic Indentation

The smoothing ball-burnishing process has commonly been used as a post-processing method to reduce the irregularities of machined surfaces. However, the mechanism of this process has rarely been examined. In this study, a simulation procedure is proposed to predict the surface roughness of a burnished workpiece under varying burnishing forces. The roughness of the workpiece surface was firstly approximated by parabolic functions. The burnishing process was then numerically simulated through two steps, namely the elastic–plastic indentation of the burnishing ball on the workpiece’s surface, and the sliding movement of the burnishing tool. The results of the simulation were verified by conducting small ball-burnishing experiments on oxygen-free copper (OFC) and Polmax materials using a load cell-embedded small ball-burnishing tool. For the OFC material, the optimal burnishing force was 3 N. The obtained experimental surface roughness was 0.18 μm, and the simulated roughness value was 0.14 μm. For the Polmax material, when the burnishing force was set at its optimal value—12 N, the best experimental and simulated surface roughness were 0.12 μm and 0.10 μm, respectively.

Optimization of the Surface Roughness and Superficial Hardness Improvement Using the Hybrid Grey-Based Taguchi Method for the Small Ball-Burnishing Process of STAVAX

2015 ◽  
Vol 649 ◽  
pp. 112-119
Author(s):  
Quoc Nguyen Banh ◽  
Fang Jung Shiou
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Condition ◽  
Surface Hardness ◽  
Principal Component ◽  
Ball Burnishing ◽  
Small Ball ◽  
Burnishing Process ◽  
Step Over ◽  
Number Of Passes

This study aims to optimize the small ball-burnishing process parameters in order to simultaneously improve the surface roughness and superficial surface hardness of the STAVAX material. A newly developed load cell embedded double spring mechanism burnishing tool was designed and fabricated. By utilizing the hybrid grey-based Taguchi method with principal component analysis (PCA) and entropy measurement the optimal process condition was the combination of the burnishing force at 10 N, the step-over at 6 μm, the number of passes at 3 times, the grease for lubricant, and the burnishing speed at 500 mm/min. The burnishing force, step-over, and the number of passes were found to have the main effects on the burnished surfaces among the five chosen control factors. The burnished surface of STAVAX material under the optimal condition was improved from Ra 0.85 to Ra 0.079 for average surface roughness, and from 67.3 HR30N to 72.7 HR30N in term of superficial hardness.

Fatigue behavior improvement of hardened parts using sequential hard turning, grinding, and ball burnishing operations

2020 ◽  
pp. 146442072095188
Author(s):  
Moosa Arsalani ◽  
Mohammad Reza Razfar ◽  
Amir Abdullah ◽  
Mohsen Khajehzadeh
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Endurance Limit ◽  
Fatigue Behavior ◽  
High Surface ◽  
Ground Surface ◽  
Fatigue Cracking ◽  
Fatigue Loading ◽  
Ball Burnishing ◽  
Burnishing Process

One of the major problems encountered in hardened components such as roller bearings, which work under fatigue loading conditions, is that the requirement of higher surface finishes (≈0.15 µm Ra) cannot be achieved by the sequential hard turning and ball burnishing processes. Such high surface qualities can be generated by additional finishing operations such as grinding. However, despite the improvement in the surface roughness, the grinding process increases both the tensile surface residual stresses and crack initiation sites on the ground surface; therefore, the fatigue behavior of the component may deteriorate. In this study, the effects of adding a grinding operation before the ball burnishing process on the fatigue behavior of AISI 4130 steel were experimentally studied. According to the achieved results, the burnished pre-ground samples show a considerable reduction in the final surface roughness and, at the same time, higher microhardness, higher endurance limit, and smaller area of the fatigue cracking zone. The burnished pre-turned and burnished pre-ground samples showed 4.24% and 10.95% improvements in the endurance limit compared to that of the turned samples, respectively.

scholarly journals Mechanism of Ball Burnishing Process for Radius of Curvature for Elastic and Plastic Deformation between Ball and Hole

2012 ◽  
Vol 9 (1) ◽  
pp. 133-138
Author(s):  
Pankaj K. Upadhyay ◽  
Pankaj Agarwal ◽  
A. R. Ansari ◽  
Ravindra Mohan
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Low Cost ◽  
Surface Hardness ◽  
Radius Of Curvature ◽  
Al Alloy ◽  
Ball Burnishing ◽  
Machine Material ◽  
Burnishing Process ◽  
Grade Material

Ball burnishing (ballizing) chip less process which produces a smooth surface and surface hardness. The pressure generated by the ball exceeds a plastic deformation stage and create a new surfaces. The plastic deformation created by ball burnishing is a cold flows under pressure into the valleys surface is smooth, Ballizing is a technique for sizing and finishing holes in metal components. It is a rapid and relatively low cost process. A suitably oversized precision ball is pressed through an unfinished undersized hole, A simple tooling such as a hardened ball and a push rod is required for this process. However an intensive analysis is essential for analysing the mechanics of the process. The ball burnishing is very useful process to improve upon surface roughness and can be employed. It will help to impart compressive stress and fatigue life can be improved. The Al alloy is a difficult to machine material and burnishing is difficult process for this grade material. A low surface roughness and hardness was obtained in increasing the operating parameters. It may develop flaw and micro cracks on the surface.

scholarly journals Influence of Ball-Burnishing Process on Surface Topography Parameters and Tribological Properties of Hardened Steel

Machines ◽  
2019 ◽  
Vol 7 (1) ◽  
pp. 11 ◽  
Author(s):  
Andrzej Dzierwa ◽  
Angelos Markopoulos
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Tribological Properties ◽  
Hardened Steel ◽  
Mean Square ◽  
Ball Burnishing ◽  
Burnishing Process ◽  
42Crmo4 Steel ◽  
Increase Wear Resistance ◽  
Steel Surfaces

The ball-burnishing process is a particular finishing treatment that can improve selected properties of different materials. In the present study, the ball-burnishing technique was used to investigate the effect of input parameters of processes on selected surface layer features like surface roughness and residual stresses of the 42CrMo4 steel surfaces. The burnishing process was conducted on Haas CNC Vertical Mill Center VF-3 using a tool with tungsten carbide tip. A further objective of our research was to improve tribological properties of the aforementioned steel by the ball-burnishing process. The results of the investigations showed that it was possible to reduce the root mean square height of the surface Sq from 0.522 μm to 0.051 μm and to increase wear resistance compared to ground samples.

scholarly journals Ball Burnishing of Mg Alloy Using a Newly Developed Burnishing Tool with On-Machine Force Control

2019 ◽  
Vol 13 (5) ◽  
pp. 619-630 ◽  
Author(s):  
Chenyao Cao ◽  
Jiang Zhu ◽  
Tomohisa Tanaka ◽  
Fang-Jung Shiou ◽  
Shunichi Sawada ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Properties ◽  
Cnc Machining ◽  
Surface Finishing ◽  
Surface Plastic ◽  
Ball Burnishing ◽  
Factors Affecting ◽  
Average Grain Size ◽  
Burnishing Process

Burnishing is a surface finishing process, in which a very smooth surface finish is obtained by pressing a ball or roller against a machined workpiece. Additionally, owing to the surface plastic deformation caused by the movement of the hardened ball or roller, other surface properties such as hardness, fatigue life, and wear resistance can be improved. Burnishing force is one of the most important factors affecting the surface modification quality. However, methods for precisely monitoring and controlling the burnishing force are rarely investigated. In this research, a novel ball burnishing tool embedded with a load-cell and air-servo system was developed and fabricated for application to a CNC machining center. Using a specially designed control software, the burnishing force in the burnishing process was monitored in real time and controlled constantly and precisely by a force feedback system. Magnesium alloy AZ31 specimens were used to evaluate the performance of the developed system. The experiments were divided into two parts. In the first part, the effects of the processing parameters on the surface roughness were investigated. The results indicated that the surface roughness could be improved from Ra= 1.95 μm to Ra= 0.26 μm. In the second part, the effects of the burnishing parameters on the surface properties were investigated by conducting experiments using Taguchi’s orthogonal array. The results suggested that the burnishing force was the most significant factors affecting the surface hardness and grain size. The Vickers hardness could be increased from HV62 to HV149. The average grain size was reduced after the burnishing process, and a work-hardening layer thickness of 0.75 mm was achieved. X-ray diffraction results indicated that the crystal orientation was modified after burnishing, and the maximum measured compressed residual stress was 186.3 MPa in the tool feed direction and 87.8 MPa in the step over direction.

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