Ultra-precision surface finish of NAK80 mould tool steel using sequential ball burnishing and ball polishing processes

Shiou, Fang‐Jung; Cheng, Chun-Der

doi:10.1016/j.jmatprotec.2007.11.235

Cited by 43 publications

(37 citation statements)

References 8 publications

(11 reference statements)

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“…Shiou and Chen [25] determined the optimal plane ball-burnishing parameters for plastic injection molding steel PDS 5 on a machining centre, utilizing the Taguchi's orthogonal array method. Basak and Goktas [26], discussed the burnishing parameters which affect to surface roughness and surface hardness on Al 7075 materials. They developed a fuzzy logic model and obtained the best parameters for the burnishing process.…”

Section: Surface Parametersmentioning

confidence: 99%

Comparative Modeling on Surface Roughness for Roller Burnishing Process using Fuzzy Logic

Al¹

2018

IJMPERD

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Roller burnishing is one of the surface finishing processes without removing of a material, where a roller rolls over the machined surface under high pressure and flattens, the roughness peaks into valley. It will improve surface finish, as well as enforces favorable compressive residual stresses and raises hardness in functional surfaces. Aluminium alloys find attractive alternate for high strength applications. In this experimental work, burnishing operation is carried out on various Aluminium alloys, such as Al 2014and Al 6063 using different burnishing parameters, such as cutting speed, feed, no of passes and depth of cut using burnishing tool. Through this experimental work, parameter that affects the surface roughness and surface hardness, on Al 2014 and 6063 material was identified and its influence on these responses was discussed.Also, the studies include the application one of the machine learning techniques is fuzzy logic, in the aspects of modeling and optimization of various process parameters applied, with roller burnishing process. This would give the comprehensive idea on choosing an optimum burnishing condition.

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Section: Surface Parametersmentioning

confidence: 99%

Comparative Modeling on Surface Roughness for Roller Burnishing Process using Fuzzy Logic

Al¹

2018

IJMPERD

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“…Depending on the hardness of material being burnished, one of two methods is used. For soft and plastic materials slide burnishing is the most frequent method [1,9,10], in which the coefficient of friction µ between the tip of the burnishing tool and rough surface of the workpiece is a decisive component for the final effect.…”

Section: Surface Milling and Burnishingmentioning

confidence: 99%

“…In case of diversified shape products with spatially complex surfaces (moulds and dies) it is common to combine rough and formed milling with finish burnishing of surfaces [1,2,3,4,5,6,7,8,9,10,11,13]. Single products, such as injection moulds for plastics or car body sheet dies have to have an appropriate state of surface geometric structure (SGS), achieved in the final machined cut [1,2,5,6,7,8,9,10,11]. Requirements that the process engineer faces are hard to be satisfied.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of Surface Geometric Structure State After Integratedformed Milling and Finish Burnishing

Berczyński

Grochała

Grządziel

2017

Management Systems in Production Engineering

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Abstract:The article deals with computer-based modeling of burnishing a surface previously milled with a spherical cutter. This method of milling leaves traces, mainly asperities caused by the cutting crossfeed and cutter diameter. The burnishing process -surface plastic treatment -is accompanied by phenomena that take place right in the burnishing ball-milled surface contact zone. The authors present the method for preparing a finite element model and the methodology of tests for the assessment of height parameters of a surface geometrical structure (SGS). In the physical model the workpieces had a cuboidal shape and these dimensions: (width × height × length) 2×1×4.5 mm. As in the process of burnishing a cuboidal workpiece is affected by plastic deformations, the nonlinearities of the milled item were taken into account. The physical model of the process assumed that the burnishing ball would be rolled perpendicularly to milling cutter linear traces. The model tests included the application of three different burnishing forces: 250 N, 500 N and 1000 N. The process modeling featured the contact and pressing of a ball into the workpiece surface till the desired force was attained, then the burnishing ball was rolled along the surface section of 2 mm, and the burnishing force was gradually reduced till the ball left the contact zone. While rolling, the burnishing ball turned by a 23° angle. The cumulative diagrams depict plastic deformations of the modeled surfaces after milling and burnishing with defined force values. The roughness of idealized milled surface was calculated for the physical model under consideration, i.e. in an elementary section between profile peaks spaced at intervals of crossfeed passes, where the milling feed f wm = 0.5 mm. Also, asperities after burnishing were calculated for the same section. The differences of the obtained values fall below 20% of mean values recorded during empirical experiments. The adopted simplification in after-milling SGS modeling enables substantial acceleration of the computing process. There is a visible reduction of the Ra parameter value for milled and burnished surfaces as the burnishing force rises. The tests determined an optimal burnishing force at a level of 500 N (lowest Ra = 0.24 µm). Further increase in the value of burnishing force turned out not to affect the surface roughness, which is consistent with the results obtained from experimental studies.

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“…Skala problemu rośnie wraz ze wzrostem wymagań funkcjonalnych stawianych wytwarzanym przedmiotom oraz ze stopniem skomplikowania opracowanej technologii. Najczęściej technolog do wytworzenia powierzchni funkcjonalnych łączy w jednej operacji różne zabiegi obróbkowe [1][2][3][4][5][6][7][8][9][10][11][13][14][15][16][17][18]. Za wartości pionowych i poziomych parametrów otrzymanej struktury geometrycznej powierzchni w dużej mierze odpowiedzialne są parametry technologiczne zrealizowanych zabiegów [1-3, 5-11, 15-18].…”

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The isotropy tests of a milled and hard-burnished surface of the X160CrMoV121 steel

et al. 2015

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StreszczenieNagniatanie staje się coraz popularniejszą obróbką wykończeniową powierzchni przedmiotów o zło-żonym przestrzennie kształcie. Coraz częściej jest stosowana w produkcji form wtryskowych, matryc i tłoczników, a więc w przypadkach, gdy oprócz wymaganej dokładności geometrycznej duży nacisk kła-dzie się na stan warstwy wierzchniej. Integrowanie nagniatania z obróbką frezowaniem pozwala na uzyskanie powierzchni, których struktura geometryczna zależy od parametrów technologicznych obu zabiegów. Obecnie trudnością, na którą napotyka technolog, jest określenie takiego stanu powierzchni frezowanej, dla którego uzyska się zadowalające efekty wykończeniowego nagniatania. W artykule przedstawiono wyniki badań, w których do określenia efektywności parametrów technologicznych stosowanych w obu rodzajach obróbki użyto -oprócz parametrów struktury geometrycznej -parametrów izotropii powierzchni. Słowa kluczowe: izotropia powierzchni, frezowanie, nagniatanie THE ISOTROPY TESTS OF A MILLED AND HARD-BURNISHED SURFACE OF THE X160CRMOV121 STEEL AbstractBurnishing becomes an increasingly popular surface finishing treatment method of objects with a spatially complex shape. It is used increasingly more often in production of injection moulds, matrixes and dies, i.e. in cases when, apart from the required geometrical accuracy, much emphasis is placed on the condition of the outer layer. Integration of burnishing with milling allows obtaining of surfaces with a geometrical structure depending on the technological parameters of both techniques. Currently, a difficulty encountered by technologists is determination of such a milled surface condition for which satisfactory effects of finishing burnishing will be obtained. The article presents the results of tests in which, apart from the geometrical structure parameters, the surface isotropy parameters were used to determine the efficiency of the technological parameters used in both machining types. Keywords: surface isotropy, milling, burnishing 641 BADANIA IZOTROPII POWIERZCHNI FREZOWANEJ I NAGNIATANEJ NA TWARDO ZE STALI X160CrMoV121Emilia BACHTIAK-RADKA 1 , Daniel GROCHAŁA 1 , Krzysztof CHMIELEWSKI 1 , Wiesław OLSZAK 1 1. FREZOWANIE I NAGNIATANIE NA TWARDO Do największych problemów we współczesnych technikach wytwarzania należy zaliczyć możliwość świadomego kształtowania warstwy wierzchniej części dostosowanej do warunków w jakich będzie eksploatowana [1][2][3][4][5][6][7][8][9][10][11]. Skala problemu rośnie wraz ze wzrostem wymagań funkcjonalnych stawianych wytwarzanym przedmiotom oraz ze stopniem skomplikowania opracowanej technologii. Najczęściej technolog do wytworzenia powierzchni funkcjonalnych łączy w jednej operacji różne zabiegi obróbkowe [1][2][3][4][5][6][7][8][9][10][11][13][14][15][16][17][18]. Za wartości pionowych i poziomych parametrów otrzymanej struktury geometrycznej powierzchni w dużej mierze odpowiedzialne są parametry technologiczne zrealizowanych zabiegów [1-3, 5-11, 15-18]. Jednak za końcową teksturę powierzchni oprócz parametrów technologicznych w du...

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Ultra-precision surface finish of NAK80 mould tool steel using sequential ball burnishing and ball polishing processes

Cited by 43 publications

References 8 publications

Comparative Modeling on Surface Roughness for Roller Burnishing Process using Fuzzy Logic

Comparative Modeling on Surface Roughness for Roller Burnishing Process using Fuzzy Logic

Modeling of Surface Geometric Structure State After Integratedformed Milling and Finish Burnishing

The isotropy tests of a milled and hard-burnished surface of the X160CrMoV121 steel

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