Experimental and Numerical Analysis of the Depth of the Strengthened Layer on Shafts Resulting from Roller Burnishing with Roller Braking Moment

Kowalik, Marek; Trzepieciński, Tomasz; Kukiełka, L.; Paszta, Piotr; Maciąg, P.; Legutko, Stanisław

doi:10.3390/ma14195844

Cited by 12 publications

(9 citation statements)

References 29 publications

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“…After ball burnishing C45 steel, it is possible to reduce the surface roughness from 3.51 μm to 0.61 μm and to increase the hardness from 202 HB to 236 HB using this process [ 43 ]. Both experimental and numerical methods are used to study the burnishing process [ 44 , 45 ].…”

Section: Introductionmentioning

confidence: 99%

Study on the Surface Layer Properties and Fatigue Life of a Workpiece Machined by Centrifugal Shot Peening and Burnishing

Skoczylas

Zaleski

2022

Materials

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This paper presents the results of research on the impact of finishing method on surface topography, surface roughness (parameters Ra, Rt, Rpk, Rk, Rvk), surface layer microhardness, residual stresses and fatigue life. Ring samples made of C45 steel were used to conduct the experiments. The following finishing machining methods were selected: slide burnishing, ball burnishing, centrifugal shot peening, centrifugal shot peening + slide burnishing and centrifugal shot peening + ball burnishing. In the first stage, the use of combined shot peening + burnishing enables microhardness to be increased on the surface layer, the values of residual stresses to be increased and the creation of characteristic machining traces on the surface, the so-called “dimples” (effect of centrifugal shot peening). On the other hand, burnishing (slide burnishing or ball burnishing) is aimed at smoothing the surface and providing favorable stereometric properties to the surface layer. It was noted that, after finishing, the surface roughness parameters decreased from 59% to 83% in relation to the reference surface. The exception is the centrifugal shot peening technology. The use of burnishing (slide or ball burnishing) after centrifugal shot peening reduces the surface roughness parameters by a maximum of 82% compared to the value after centrifugal shot peening. The highest increase in microhardness was obtained after centrifugal shot peening + slide burnishing (ΔHV = 105 HV 0.05), while the highest thickness gh (gh = 120 μm) was obtained after centrifugal shot peening + ball burnishing. The combination of centrifugal shot peening and ball burnishing results in the highest absolute value of compressive residual stresses σmax = 602 MPa and depth gσ = 0.41 mm). Application of an additional operation after centrifugal shot peening increases fatigue life from 27% to 49%. ANOVA analysis of variance confirms the significance of the processing effect of centrifugal shot peening combined with slide burnishing (CSP + SB) and centrifugal shot peening + ball burnishing (CSP + BB) on the analyzed dependent surface.

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Section: Introductionmentioning

confidence: 99%

Study on the Surface Layer Properties and Fatigue Life of a Workpiece Machined by Centrifugal Shot Peening and Burnishing

Skoczylas

Zaleski

2022

Materials

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“…As a result, for successive discrete moments of time τ 0, Δt, 2Δt, … the geometry of the body and the states of incremental displacements, displacement velocities, accelerations, strains, strain rates, and stresses are determined. The concept of incremental description has already been verified by the author and was used to describe other plastic-forming processes: cutting [36][37][38][39][40][41][42], thread rolling [15][16][17]28,29], burnishing rolling [43][44][45][46][47][48][49], drawing [50][51][52], grinding with a single abrasive grain [53], calculating the fatigue strength of products [54][55][56], and diamond sliding burnishing [56].…”

Section: The Concept Of Incremental Descriptionmentioning

confidence: 99%

Application of the FEM Method to Modeling and Analysis of the Cold Thread Rolling Process—Part 1: Conditions for Ensuring a Plane State of Deformations

Kukiełka

2023

Materials

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The article concerns the application of the FEM method for the prediction of stress and deformation states in a workpiece during the thread rolling process (TR). The analysis covered a new kinematic variant of the TR process in which the basket of the head rotates and is torque-driven, while the workpiece is stationary and the head with the rollers moves axially relative to the workpiece. The TR process was considered as a geometrical and physical non-linear initial and boundary problem with non-linear, moving, and variable in time and space boundary conditions. The boundary conditions in the contact areas of the tool with the workpiece were unknown. An updated Lagrange (UL) description was used to describe the physical phenomena at a typical incremental step. The states of strain and strain rate were described by non-linear relationships without linearization. New discrete systems of motion and deformation equations of the object in the TR were introduced, which take into account the change in the stiffness of the system during the TR process. This equation was solved by the central differences method (explicit). The material parameters were estimated during tensile tests to determine the characteristics of the C45 steel, and a new semi-empirical method was used to determine the relationship yield stress, effective true strain, and effective true strain rate in the thread rolling process. A modified Cowper–Symonds material model was also used to model the displacement process of the wedge on an elastic/visco-plastic body reflecting the TR process. A non-linear dependency of material hardening module depending on strain and strain rate was introduced. To confirm the plane state of deformation and spatial state of stress, an experimental investigation was carried out. The computer models were validated, and a good convergence of the results was obtained. Applications in the ANSYS/LS-Dyna program were developed to simulate the TR process. The developed applications enable a comprehensive time analysis of the states of displacement, strain, and stress occurring in an object consisting of a workpiece (shaft) and a tool (roller) for the case of a plane strain state and a spatial stress state. Exemplary results of numerical analyzes are presented to explain the influence of the friction coefficient on the condition of the thread quality, and the state of deformations and stresses were shown.

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“…Burnishing involves impacting the surface of the workpiece with a smooth and hard burnishing element, with the force of this impact maintained at an approximately constant value [19,20].…”

Section: Introductionmentioning

confidence: 99%

Study on selected properties of the surface layer of magnesium alloys after impulse shot peening

Skoczylas,

Zaleski,

Ciecieląg

et al. 2024

Preprint

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Shot peening is a commonly used method of finishing machine elements in the manufacturing process. One variation of shot peening is the impulse shot peening. This paper presents the influence of impulse shot peening technological conditions on the surface roughness (parameters Ra and Rt) and topography, microhardness. The FEM was used to determine the S11 stresses. In the experiment and simulation tests, AZ31 and AZ91HP magnesium alloy samples were used. Variable parameters in the impulse shot peening process were: impact energy E: 15 ÷ 185 mJ, ball diameter d: 3 ÷ 15 mm and impact density j: 3 ÷ 44 mm− 2. As a result of the tests carried out, it was found that after impulse shot peening, the surface topography is change, microirregularities are flattened, numerous depressions are formed, which can be potential lubrication pockets. The 2D surface roughness parameters for most impulse shot peening conditions are lower than for the pre-machining. The roughness parameters for magnesium alloy AZ91HP are lower than for AZ31. This is most likely due to the lower elongation A. The microhardness after impulse shot peening increased by 20 HV to 87 HV. As a result of FEM of the impulse shot peening, compressive stresses S11 were created in the surface layer. The depth of occurrence of S11 stresses is from 1.5 to 3.5 mm, and their value for the AZ91HP magnesium alloy samples are 10–25% lower than for the AZ31 alloy samples. The most favorable results of the tested properties of the surface layer were obtained for E = 100 mJ, d = 10 mm, j = 11 mm− 2.The abstract serves both as a general introduction to the topic and as a brief, non-technical summary of the main results and their implications.

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Experimental and Numerical Analysis of the Depth of the Strengthened Layer on Shafts Resulting from Roller Burnishing with Roller Braking Moment

Cited by 12 publications

References 29 publications

Study on the Surface Layer Properties and Fatigue Life of a Workpiece Machined by Centrifugal Shot Peening and Burnishing

Study on the Surface Layer Properties and Fatigue Life of a Workpiece Machined by Centrifugal Shot Peening and Burnishing

Application of the FEM Method to Modeling and Analysis of the Cold Thread Rolling Process—Part 1: Conditions for Ensuring a Plane State of Deformations

Study on selected properties of the surface layer of magnesium alloys after impulse shot peening

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