Numerical Simulation and Experimental Validation of Surface Roughness by the Smoothing Small Ball-Burnishing Process

Abstract

The smoothing ball-burnishing process has commonly been used as a post-processing method to reduce the irregularities of machined surfaces. However, the mechanism of this process has rarely been examined. In this study, a simulation procedure is proposed to predict the surface roughness of a burnished workpiece under varying burnishing forces. The roughness of the workpiece surface was firstly approximated by parabolic functions. The burnishing process was then numerically simulated through two steps, namely the elastic–plastic indentation of the burnishing ball on the workpiece’s surface, and the sliding movement of the burnishing tool. The results of the simulation were verified by conducting small ball-burnishing experiments on oxygen-free copper (OFC) and Polmax materials using a load cell-embedded small ball-burnishing tool. For the OFC material, the optimal burnishing force was 3 N. The obtained experimental surface roughness was 0.18 μm, and the simulated roughness value was 0.14 μm. For the Polmax material, when the burnishing force was set at its optimal value—12 N, the best experimental and simulated surface roughness were 0.12 μm and 0.10 μm, respectively.

Changes in Areal Surface Textures Due to Ball Burnishing

“…The plastic deformation of the M1 surface was likely easier than that of the M2 surface. The possibility of obtaining a smoother surface due to burnishing is important because in [24,34,37], the lowest roughness height led to the smallest friction and wear.…”

“…Attabi et al [19] reduced the surface amplitude by more than 90% via the application of ball burnishing. Banh et al [24] simulated and experimentally verified the effect of ball burnishing on a decrease in the average height. The smallest roughness height was achieved for the medium value of the burnishing force.…”

Evaluating Some Functional Properties of Surfaces with Partially Regular Microreliefs Formed by Ball-Burnishing

“…Banh et al [24] investigated the force which is applied when pressing the ball during burnishing, and its effect on the treated surface and the variation of its roughness. They proposed a numerical model that describes the surface burnishing process using a ball, which consists of two stages: the elastic-plastic pressing of the ball into the workpiece surface, and the sliding movement of the ball tool along the treated surface.…”

The Influence of Diamond Burnishing Process Parameters on Surface Roughness of Low-Alloyed Aluminium Workpieces

“…In this work, the surface points of the workpiece were determined with the physical measurement points that were imported to the DEFORM FE code [17]. Banh et al [18] also dealt with the numerical simulation of the effect of burnishing force on surface roughness, but they described the pre-burnishing surface roughness with parabolic approximation. This made the study more complicated, but the measured and simulated values still show a good approximation, so their model can be applied correctly.…”