Jumping Wave Characteristic during Low Plasticity Burnishing Process

Abstract

During the low plasticity burnishing process of soft materials such as carbon steel with a hardness of up to 40 HRC (Rockwell grade) a raised structure of the material known as the Jumping Wave forms in front of the tool roll. This phenomenon significantly disturbs the burnishing process, but is very poorly described in the literature. This article presents studies of this phenomenon on the example of burnished 1.0562 steel. The research concerns the changes in the surface structure of the processed material as well as changes in the structure of the material during this process. The research shows changes in the geometric structure of the surface made in the 3D system and their parametric description. Moreover, the work presents an analysis of the metallographic structure in the tool zone. The research showed occurrence of material slippages in the wave in front of the tool, which creates an additional structure on the surface. These tests make it possible to better understand the process of changes that take place in the surface layer of the processed element in the low plasticity burnishing process.

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

“…Movement of the roller in relation to the material, which is a combination of burnishing speed and feed motion, causes most of the flowing material to accumulate in front of the tool. The creation of an additional material structure in front of the tool is noted in the literature and in workshop slang is referred to as the “jumping wave” [ 36 , 37 ] or “the wave of plastically deformed material” [ 22 ]. The equivalent plastic strain values in the zone of the “jumping wave” have much higher values (point B in Figure 21 a) than in the stable burnishing zone.…”

A Review of Low‐Plasticity Burnishing and Its Applications

“…To minimize the surface roughness, the rolling speed, pressure, and the number of passes should be set at high levels; on the contrary, the ball diameter should be at a low level, because of a strong interplay between rolling speed and ball diameter. In addition, Dzionk et al [ 69 ] investigated the jumping‐wave (raised structure) characteristics of a type of carbon steel during LPB when the hardness was strengthened up to 40 HRC. They found that jumping waves formed in the front of the LPB tool, thereby significantly affecting the stability of the burnishing process.…”