Finite element analysis of ball burnishing process: comparisons between numerical results and experiments

Sayahi, M.; Sghaier, Salem; Belhadjsalah, Hédi

doi:10.1007/s00170-012-4599-9

Cited by 68 publications

(45 citation statements)

References 12 publications

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“…To reduce computational time, the parts which would not have deformation were modeled as rigid bodies; these parts are shown in Figure 3.2, the extremes (red) and the ball (purple); considering the ball as rigid body as is used for other authors [6,16]. The cylinder was modeled hollow because the stresses are neglected in the center [28] due the residual stress is produced approximately 1 mm depth or less below surface [3,6,16]. Besides these considerations, only on the zone to be burnished was added roughness (Figure 3.2b).…”

Section: Simulation Of Ball-burnishing Process With Roughnessmentioning

confidence: 99%

“…In the past, most studies concerning to the ball burnishing process were focused on experimental tests [2][3][4][5][11][12][13][14][15], determining specific parameters such as the roughness before and after the burnishing process. In recent years, some researchers developed 2D and 3D models using the Finite Element Method (FEM) [1,3,6,[16][17][18][19] to predict, study and analyze the influence of parameters of the burnishing ball process, allowing to reduce the high costs of experimental tests. The study of models has been focused on the prediction of compressive residual stress and the prediction of roughness simulating the burnishing process has been little studied.…”

Section: Introductionmentioning

confidence: 99%

“…The study of models has been focused on the prediction of compressive residual stress and the prediction of roughness simulating the burnishing process has been little studied. Some studies did not consider the roughness profile in the finite element model [16][17][18], some other considered it as a profile of semicircular [3,6] or triangular [19] patterns, both with similar characteristics corresponding to the machining process prior to burnishing; another study used linear interpolation of the measured data points to obtain a 2D profile of roughness [2]. Different manufacturing processes generate surface irregularities with diverse amplitudes and patterns, so to predict the surface finish by FEM, the modelation of these irregularities must be investigated.…”

Section: Introductionmentioning

confidence: 99%

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FEM burnishing simulation including roughness

et al. 2015

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Ball burnishing is a surface improvement process that provides compressive residual stresses and increment the hardness in the surface layer of workpieces. Actually, in the state of the art some papers use FEM to simulate the burnishing process in the most cases without consideration the roughness of the workpiece, in other cases the roughness is considered only as two-dimensional semicircular or triangular periodic pattern. In other studies to simulate three-dimensional roughness, the two dimensional case is extruded. In this paper, a new way to simulate three-dimensional random roughness was used to simulate the ball burnishing process obtaining the final roughness and residual stresses distribution in the surface and below it. For the simulation, a commercial explicit FEA Software was used considering a bilinear material model. The finite element model of ball burnishing process was validated with experimental test and the methodology of this simulation process is presented. Keywords: burnishing, surface roughness, FEM simulation Streszczenie: Nagniatanie jest procesem stosowanym w celu poprawy powierzchni, który zapewnia ściskające naprężenia szczątkowe i wzrost twardości w warstwie wierzchniej przedmiotów obrabianych. Według aktualnego stanu wiedzy w kilku przypadkach do symulacji procesu nagniatania używano MES, jednakże w większości przypadków nie uwzględniono chropowatości powierzchni przedmiotu obrabianego, a w innych chropowatość była traktowana jako dwuwymiarowy powtarzalny kształt półokrągły lub trójkątny. W innych badaniach, do symulacji chropowatości trójwymiarowej użyto modelu powstałego przez wyciągnięcie przypadku dwuwymiarowego. W niniejszej pracy użyto nowego sposobu

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Section: Simulation Of Ball-burnishing Process With Roughnessmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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FEM burnishing simulation including roughness

et al. 2015

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“…The finite element method is used for simulation of different plastic workings: rolling, forging and pressing, drawing and other [6][7][8][9][10][11][12]. Numerical analysis based on the elastic and elastic/ visco-plastic bodies is used for theoretical analysis of a contact surface of the spherical tool and the workpiece [13][14][15].…”

Section: Introductionmentioning

confidence: 99%

The Numerical and Experimental Analysis of Ballizing Process of Steel Tubes

Dyl

2017

Archives of Metallurgy and Materials

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This paper presents chosen results of experimental and numerical research of ballizing process of the steel tubes. Ballizing process is a method of burnishing technology of an internal diameter by precisely forcing a ball through a slightly undersized premachined tubes. Ballizing process is a fast, low-cost process for sizing and finishing tubes. It consists of pressing a slightly oversized ball through an unfinished tube to quickly bring the hole to desired size. The ball is typically made from a very hard material such as tungsten carbide or bearing steel. Ballizing process is by cold surface plastic forming of the surface structure, thereby leaving a layer of harder material and reducing its roughness. After theoretical and experimental analysis it was determined that the smaller the diameter of the balls, the bigger intensity of stress and strain and strain rate. The paper presents influence of ballizing process on the strain and stress state and on the surface roughness reduction rate of the steel tubes.

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“…It was observed that the mechanism of formation and flow of the ridge played a key role, but the numerical models were inaccurate in predicting surface geometries and mechanical characteristics. Sayahi et al [22] presented 2-D and 3-D FE modelling of the ball burnishing process. An elasto-plastic material model was assumed in the framework of the FE analysis.…”

Section: Introductionmentioning

confidence: 99%

Modelling of the ball burnishing process with a high-stiffness tool

Ranđelović

Tadić

Todorovič

et al. 2015

Int J Adv Manuf Technol

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This paper deals with the problem of forming a surface roughness profile of a machined surface and a definition of the optimal depth of penetration in ball burnishing which would allow minimization of surface roughness. The assumptions, which have been numerically and experimentally verified, claim that maximum surface quality, i.e., minimum surface roughness, Ra, is achieved when the depth of ball penetration into the workpiece material is approximately equal to the maximum peak height, Rp. For the purpose of numerical simulations, a surface roughness model based on milling kinematics was used. Numerical simulations and the used roughness model support the claim that penetrating with a stiff tool up to the mean line of the roughness profile yields best surface quality. The authors maintain that ball penetrations, which exceed Rp, cannot significantly improve surface quality. Furthermore, the phenomenon of profile peak deformation is substantially clarified. The analysis of internal stresses within the workpiece after ball burnishing allowed a relationship to be established between internal stress distribution along the depth of the hardened layer and ball penetration depth.

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Finite element analysis of ball burnishing process: comparisons between numerical results and experiments

Cited by 68 publications

References 12 publications

FEM burnishing simulation including roughness

FEM burnishing simulation including roughness

The Numerical and Experimental Analysis of Ballizing Process of Steel Tubes

Modelling of the ball burnishing process with a high-stiffness tool

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