Analysis of contact elastic-plastic strains during the process of burnishing

Skalski, Konstanty; Morawski, A.; Przybylski, Włodzimierz

doi:10.1016/0020-7403(94)00083-v

Cited by 34 publications

(13 citation statements)

References 4 publications

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“…In spite of several research papers in which deep-rolling in particular [14,[21][22][23][24][25][26], or the contact in general between a sliding or rolling element and a workpiece that deforms plastically [27][28][29][30][31][32][33] is examined, there is, to date , no fundamental understanding of the overlapping elastic and plastic processes that take place during the rolling operation.…”

Section: Experiments and Discussionmentioning

confidence: 99%

Fundamentals of the Deep Rolling of Compressor Blades for Turbo Aircraft Engines

Klocke

Mäder

2005

steel research international

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The weakening of the fatigue strength of turbine blades due to local impact damage caused by foreign objects (Foreign Object Damage ‐ FOD) represents a significant safety risk in modern civil and military aviation. It is possible to employ deep rolling to counteract such component weakening in a particularly effective way. Although deep rolling has long been used on rotationally symmetric components, the underlying deformation processes are largely unknown. The deep rolling of thin‐walled free‐form surfaces, such as those on turbine blades, represents a new, demanding production challenge. For this reason, this paper describes the implementation of a deep‐rolling process for machining thin‐walled turbine blades and, by combining practical and numerical test results, outlines some of the underlying deformation processes.

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Section: Experiments and Discussionmentioning

confidence: 99%

Fundamentals of the Deep Rolling of Compressor Blades for Turbo Aircraft Engines

Klocke

Mäder

2005

steel research international

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“…To apply these processes, the desired material properties could be achieved by controlling the grain size which is the critical microstructural factor influencing the mechanical behavior of the metallic work materials and their chemical response to the surrounding environments [2]. Burnishing is a SPD process to induce high strain and strainrate [3] for the purpose of improving the surface integrity of the manufactured components. Grzesik and Zak [4] reported that lower surface roughness was obtained by ball burnishing of 41Cr4 low-alloy steel with 60 HRC hardness.…”

Section: Introductionmentioning

confidence: 99%

Surface Layer Modification by Cryogenic Burnishing of Al 7050-T7451 Alloy and Validation with FEM-based Burnishing Model

et al. 2015

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As one of the chipless machining processes, burnishing has been performed on manufactured components as the final operation to improve the surface integrity, including reduced surface roughness and increased surface and subsurface hardness. Refined surface layers with ultra-fine grains or nano-grains could be generated during the burnishing process due to imposed severe plastic deformation and the associated dynamic recrystallization (DRX). These harder layers with compressive residual stresses induced by the burnishing process also provide added benefits by enhancing wear/corrosion resistance and increasing the fatigue life of the components. The research findings presented in this paper show the effects of cryogenic burnishing with roller burnishing tool on Al 7050-T7451 alloy, using liquid nitrogen as the coolant. Burnishing forces and temperatures are measured to compare the differences between dry and cryogenic burnishing. Higher tangential forces and lower temperatures are observed from cryogenic burnishing due to the work-hardening and the rapid cooling effects introduced by cryogenic burnishing. Also, refined layers with nano-grains (grain size of approximately 40 nm) are formed in the cryogenically burnished surface, in which an average hardness increase of 9.5%, 17.5% and 24.8% within the 200 m depth are achieved in comparison with the hardness values obtained from dry burnishing, at the corresponding burnishing speeds of 25, 50 and 100 m/min. A finite element model (FEM) is developed to simulate the burnishing forces and temperatures for validation of the experimental results, based on the modified Johnson-Cook flow stress model combined with the constitutive equations concerning DRX. Good agreement is obtained between the predicted and experimental results.

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“…In recent years, with the rapid developments of computer technology and numerical calculation, numerical simulations especially those based on Finite Element Method (FEM) attracting many scholars' attentions, many valuable researches were made. Skalski studied the burnishing indentation process of burnishing ball into workpiece using axisymmetric FEM to analyze the relations between contact pressure, plastic strain depth and burnishing force [9]; Bouzid and Sa developed a 3D FEM model of the burnishing indentation process to analyze the residual stress induced [10]; Beres et al (Zhuang and Wicks) analyzed the residual stress and cold-work hardening induced after single-pass and multi-pass of LPB on Ti-6Al-4V (IN718) using the commercial non-linear finite element software MSC.Marc (ABAQUS) [11,12]; Röttger made a 2D planestrain FEM analysis of ball burnishing on the hardened steel using DEFORM-2D [13]; Sartkulvanich et al developed more perfect 2D and 3D FEM models to analyze the influence of burnishing parameters on surface roughness and residual stress based on Röttger's work [14]. FEM is a very strong and comprehensive technique which can take almost all the burnishing factors into consideration to find out the facts or study the burnishing mechanisms in a way that no other tools can accomplish.…”

Section: Introductionmentioning

confidence: 99%

Analytical prediction and experimental verification of surface roughness during the burnishing process

Xia

Zhou

et al. 2012

International Journal of Machine Tools and Manufacture

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Analysis of contact elastic-plastic strains during the process of burnishing

Cited by 34 publications

References 4 publications

Fundamentals of the Deep Rolling of Compressor Blades for Turbo Aircraft Engines

Fundamentals of the Deep Rolling of Compressor Blades for Turbo Aircraft Engines

Surface Layer Modification by Cryogenic Burnishing of Al 7050-T7451 Alloy and Validation with FEM-based Burnishing Model

Analytical prediction and experimental verification of surface roughness during the burnishing process

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