Characterization of Surface Integrity Produced by Sequential Dry Hard Turning and Ball Burnishing Operations

Abstract

This paper presents the state of surface integrity produced on hardened-high strength 41Cr4 steel after hard machining and finish ball burnishing. Surfaces machined by sequential machining processes were characterized using 2D and 3D surface roughness parameters. Moreover, detailed functionality of the generated surfaces was performed using a set of 3D functional roughness parameters. Among the characteristics of the surface layer, its microstructure, the distribution of microhardness and the residual stresses were determined. This investigation confirms that ball burnishing allows producing surfaces with lower surface roughness and better service properties than those generated by cubic boron nitride (CBN) finish hard turning operations.

Prediction of the Functional Performance of Machined Components Based on Surface Topography: State of the Art

“…New methods of characterizing and measuring both geometrical and physical properties of surface integrity produced by conventional cutting and abrasive machining operations are described in Ref 15 and 16. Extended characterization of surface roughness and surface texture produced by different finishing processes on hardened steel parts is presented by Grzesik et al for hard turned and ball burnished surfaces (Ref [17][18][19], and comparatively for hard turned, CBN ground, belt ground and superfinished surfaces (Ref 18,20). Figures 14 and 15 show the comparison of the values of three functional (bearing) parameters-reduced core height (Sk), reduced peak height (Spk) and reduced valley height (Svk), and corresponding three functional indexes-surface bearing index (Sbi), core fluid retention index (Sci) and valley fluid retention index (Svi), respectively.…”

Possibilities of the Generation of Hardened Steel Parts With Defined Topographic Characteristics of the Machined Surfaces

“…Rao et al [11] have investigated how surface morphology varies in ultraprecision machining. The 2D and 3D comparison, more oriented on bearing area parameters, related to PHT and belt grinding is provided by Grzesik et al [9,12], Nowadays, the technological shifts in surface metrology allow the surface features generated by modern manu facturing processes (including hard part machining) to be charac terized with higher accuracy using a number of the field parameters (.S'-parameters and V-parameters sets) [13]. In this study, surface textures of representative hard turned and differ ently ground surfaces with the Sa parameter of about 0.2 pm are characterized and compared using a number of standardized 3D roughness parameters as well as other characteristics such as frac tal dimension and motif and frequency parameters.…”

Surface Texture Analysis of Hardened Shafts after Ceramic Ball Burnishing

“…Machining hard materials (hardened steel, cast iron alloys whose hardness exceeds 40 HRC) is a very efficient and cheap subtractive method. Tools for machining hard materials, for example, cutting inserts (CBN—cubic boron nitride, for machining hardened parts of up to 65 HRC) [19,20], are available in the market; however, obtaining the desired surface roughness parameters is not always possible. In this case, the surface can be improved by burnishing; however, this process has a different course than in case of burnishing soft materials [18,21,22,23,24].…”