An investigation of ball burnishing process on CNC lathe using finite element analysis

John, Merbin; Wilson, AR; Bhardwaj, Ajay; Abraham, Avinav; Vinayagam, B. K.

doi:10.1016/j.simpat.2016.01.004

Cited by 38 publications

(24 citation statements)

References 11 publications

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“…Uddin et al 9 developed a three-dimensional (3D) FE model of ball burnishing between a ball and a plate using Johnson–Cook constitutive model, and the investigation of the influence of process parameters on the surface integrity was carried out. John et al 10 investigated the ball burnishing process on computer numerical control (CNC) lathe by two-dimensional (2D) FE model with Johnson–Cook constitutive model, and the effect of process parameters on the roughness and residual stress were investigated. Zhang et al 11 established a 3D model of the roller burnishing process between a roller and a plate using an exponential hardening model.…”

Section: Introductionmentioning

confidence: 99%

Investigation of residual stress distribution induced during deep rolling of Ti-6Al-4V alloy

Han

Zhang

Yao

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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To clarify the effects of deep rolling parameters on residual stress, two-dimensional and three-dimensional finite element models were developed using the Chaboche hardening model. Both two-dimensional and three-dimensional simulation results were compared with experimental results. The three-dimensional model is more accurate, especially the 90° cut-out model. The maximum errors in the longitudinal and circumferential directions of 90° cut-out are 8.9% and 15.6%, respectively. Compared to 20 MPa, a rolling pressure of 38 MPa results in larger and deeper compressive residual stress in both directions, but lower surface residual stress in the circumferential direction. Compared to 30% overlap, 60% overlap produces larger compressive residual stress in the near surface region in the longitudinal direction and deeper residual stress with lower maximum compressive residual stress in the circumferential direction. The friction coefficient only slightly affects residual stress in the circumferential direction; increasing the rolling speed induces higher near surface residual stress in the circumferential direction. Compared to the HG6 tool, the HG8 tool generates decreasing surface residual stresses and deeper residual stress in both directions. Compared to one pass, two passes significantly increase the residual stress in circumferential direction, but only slightly increase the residual stress in the longitudinal direction.

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Section: Introductionmentioning

confidence: 99%

Investigation of residual stress distribution induced during deep rolling of Ti-6Al-4V alloy

Han

Zhang

Yao

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…At present, the manufacturing industry is focusing much attention on dimensional accuracy and surface finish. Surface quality depends largely on the applied finishing treatments, and on the values of input parameters used in them [1]. One of the major possible predictors of machining performance is through the deep analysis of surface textures [2].…”

Section: Introductionmentioning

confidence: 99%

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

Dzierwa

Markopoulos

2019

Machines

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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.

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“…This parameter governs the modeling of the surface interactions of helical burnishing. The contact model usually used is a Coulomb model [5] [13] [14]. Like Balland et al [5], we used a master-slave contact algorithm where the friction was taken into account using a penalty method and a value of 0.2.…”

Section: )mentioning

confidence: 99%

Investigation of Aluminum Alloy Properties During Helical Roller Burnishing Through Finite Element Simulations and Experiments

Souop

Daidié

Landon

et al. 2019

Advances on Mechanics, Design Engineering and Manufacturing II

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Industry is always looking for ways to increase the lifetime of assemblies, especially the fatigue lifetime, from the production phase of fastening holes onwards. Helical roller burnishing is presented here as an innovative mechanical surface treatment. Applied directly after orbital drilling, this technique induces superficial plastic strains that reduce surface roughness and increase hardening and compressive residual stresses. Several studies on 3D finite element models of burnishing have been carried out but they are very time-consuming. In this review, a comparative numerical study of helical burnishing (in terms of calculation time and results on residual stress) between one 3D and two 2D plane strain finite element simulations is performed on 2024-T351 aluminum alloy drilled parts. The impact of the process operating parameters is also investigated. This comparison shows fairly similar results regarding the residual stress profiles but levels are rather different. This could be explained by the kinematics of complex helical roller burnishing, which is strongly three-dimensional. The numerical results of one of the cases studied reveal compressive residual stresses of around-100 MPa and-490 MPa in the radial and circumferential directions of the hole, respectively. Burnishing depth and spindle rotation speed have a great impact on the final residual stress profiles. These simulations are then confronted with experimental results obtained during tests carried out using an orbital drilling unit (ORBIBOT). This demonstrates the interest of the modeling implemented and also points out ways to improve the models developed.

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An investigation of ball burnishing process on CNC lathe using finite element analysis

Cited by 38 publications

References 11 publications

Investigation of residual stress distribution induced during deep rolling of Ti-6Al-4V alloy

Investigation of residual stress distribution induced during deep rolling of Ti-6Al-4V alloy

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

Investigation of Aluminum Alloy Properties During Helical Roller Burnishing Through Finite Element Simulations and Experiments

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