Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

Nguyen, Trung Thanh; Le, Chi-Hieu

doi:10.1177/0954405420976661

Cited by 10 publications

(5 citation statements)

References 27 publications

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Section: Introductionmentioning

confidence: 95%

“…Furthermore, the combination of turning and burnishing processes is confirmed to be feasibility for improving surface quality, energy reduction, and cost-effectiveness. 12,13 In addition to significantly reducing roughness, the results also indicated that the energy consumption and production cost could be decreased by 20.15% and 17.19%. In recent years, ultrasonic-assisted burnishing (UB) has developed rapidly and has been widely used in the field of surface modification because of the formation of deep compressive residual stress and surface work hardening, and decrease of surface roughness. Hence, the high-quality and high-efficient machining of the laser cladded layers is prone to be achieved with the combination of turning and UB treatment.…”

Section: Introductionmentioning

confidence: 98%

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Improving the surface integrity of laser cladded layer by ultrasonic-assisted burnishing at medium temperature with considering initial surface conditions

Zhang

Jin

Jiang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Improving the surface integrity of laser cladded layer via burnishing is an important research topic in remanufacturing field. However, the initial surface roughness condition induced by mechanical machining generates great influence on the strengthening mechanism of subsequent burnishing. In this study, the effects of ultrasonic-assisted burnishing (UB) and ultrasonic-assisted warm burnishing (UWB) on the surface integrity of laser cladded layer were analyzed when treated on different surface conditions obtained by turning with different feed parameters. The results indicated that both the UB and UWB treatments would cause great improvements in microhardness, surface roughness including height and functional parameters, and residual stress of the laser cladded layer when compared to those by turning. First, the severe plastic deformation in UB and UWB treatments counteracted the thermal softening effect in turning process, so that the machined surface could maintain high hardness. Second, UB treatment reduced the roughness by 70% compared with turning, while the surface roughness after UWB treatment was even 30% lower than that obtained by UB. Third, the tensile residual stress shifted to deep compressive state by both UB and UWB treatments, though the thermal load in UWB generated a negative effect on generating compressive residual stress. According to the surface integrity evaluation results by radar diagrams, turning with feed f = 0.2 mm/r and UWB is preferred in machining of the laser cladded layer for enhanced surface integrity. On the basis of this research, it is expected to achieve the purpose of high-efficiency and high-quality cutting of the laser cladded layer.

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Section: Introductionmentioning

confidence: 95%

Section: Introductionmentioning

confidence: 98%

Improving the surface integrity of laser cladded layer by ultrasonic-assisted burnishing at medium temperature with considering initial surface conditions

Zhang

Jin

Jiang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…In earlier studies of the ball burnishing process, the Taguchi method [43][44][45][46][47][48][49][50] and response surface methodology (RSM) [51][52][53][54][55][56] were widely used. The Taguchi method reduces the number of experiments required for analysis but considers only the main effects on the process and does not allow consideration of the interaction between the input variables.…”

Section: Introductionmentioning

confidence: 99%

The Modelling of Surface Roughness after the Ball Burnishing Process with a High-Stiffness Tool by Using Regression Analysis, Artificial Neural Networks, and Support Vector Regression

Kanović

Vukelić

Šimunović

et al. 2022

Metals

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Surface roughness is an important indicator of the quality of the machined surface. One of the methods that can be applied to improve surface roughness is ball burnishing. Ball burnishing is a finishing process in which a ball is rolled over the workpiece surface. Defining adequate input variables of the ball burnishing process to ensure obtaining the required surface roughness is a typical problem in scientific research. This paper presents the results of experiments to investigate ball burnishing of AISI 4130 alloy steel with a high-stiffness tool and a ceramic ball. The experiments were conducted following a randomized full factorial design for different levels of input variables. The input variables included the initial arithmetic mean roughness (the initial surface roughness), the depth of ball penetration, the burnishing feed, and the burnishing ball diameter, while the output variable was the arithmetic mean roughness after ball burnishing (the final surface roughness). The surface roughness modeling was performed based on the experimental results, using regression analysis (RA), artificial neural network (ANN), and support vector regression (SVR). The regression model displayed large prediction errors at low surface roughness values (below 1 μm), but it proved to be reliable for higher roughness values. The ANN and SVR models have excellently predicted roughness across a range of input variables. Mean percentage error (MPE) during the experimental training research was 29.727%, 0.995%, and 1.592%, and MPE in the confirmation experiments was 34.534%, 1.559%, and 2.164%, for RA, ANN, and SVR, respectively. Based on the obtained MPEs, it can be concluded that the application of ANN and SVR was adequate for modeling the ball burnishing process and prediction of the roughness of the treated surface in terms of the possibility of practical application in real industrial conditions.

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“…To decrease environmental impacts and obtain sustainable manufacturing, the energy consumed and carbon emissions should be minimized for the rotary turning operation. 21,22 The empirical models of the average roughness, turning forces, and cutting temperature for various ADRT processes have been proposed in the previous publications. Unfortunately, the comprehensive models of the total specific energy and carbon emission have not been developed.…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization of the actively driven rotary turning for energy efficiency, carbon emissions, and machining quality

Nguyen

Duong

Mia

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Boosting energy efficiency and machining quality are prominent solutions to achieve sustainable production for turning operations. In this work, a machining condition-based optimization has been performed to decrease the total specific energy (SEC), carbon emission (CE), and average roughness (AR) of the actively driven rotary turning (ADRT) process. The processing factors are the tool rotational speed (Tv), depth of cut (a), feed rate (fr), and workpiece speed (Wv). The turning experiments of the mold material labeled SKD11 have been conducted on a CNC lathe. The regression method is employed to develop comprehensive models of the total specific energy, carbon emissions, and average roughness. The entropy approach is then applied to drive out the weight value of each ADRT response. Finally, the non-dominated sorting particle swarm optimization (NSPSO) is utilized to determine the optimal parameters. The findings indicated that the optimal values of the Tv, a, fr, and Wv are 77 m/min, 0.32 mm, 0.25 mm/rev., and 128 m/min, respectively. The SEC, AR, and CE are decreased by 18.07%, 10.46%, and 5.02%, respectively, as compared to the initial approach. Moreover, the developed active rotary turning operation can be considered as an effective technical solution to boost the machining efficiency of hardened steels.

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Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

Cited by 10 publications

References 27 publications

Improving the surface integrity of laser cladded layer by ultrasonic-assisted burnishing at medium temperature with considering initial surface conditions

Improving the surface integrity of laser cladded layer by ultrasonic-assisted burnishing at medium temperature with considering initial surface conditions

The Modelling of Surface Roughness after the Ball Burnishing Process with a High-Stiffness Tool by Using Regression Analysis, Artificial Neural Networks, and Support Vector Regression

Multi-response optimization of the actively driven rotary turning for energy efficiency, carbon emissions, and machining quality

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