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Modeling and Pareto Optimization of Burnishing Process for Surface Roughness and Microhardness
Published in Ganesh M. Kakandikar, Dinesh G. Thakur, Nature-Inspired Optimization in Advanced Manufacturing Processes and Systems, 2020
Burnishing, a post-machining process, is used to improve the external topography of surfaces (surface finish), microstructure, mechanical properties (microhardness), and residual stresses of the internal subsurface layer. The process is initially used in automobile components, including pistons, connecting rod bores, brake system components, transmission parts, and torque converter hubs. Nowadays, it is also used in non-automotive applications such as pistons, piston rods, and cylinders for the hydraulic or pneumatic system. In the hydraulic or pneumatic system, the surface is critical in the longevity and sealing properties. If the surface is too rough, oil is allowed to pass under the seal through the “valleys,” causing oil to leak by the seal. A very smooth surface prevents the oil to pass under the seal. These increase the wear of the seal. For the lubrication of the seal, it is essential that a small amount of oil should pass under the seal. If the surface is too rough, an excess amount of oil passes under the seal, hence causing leakage. Hence, it is necessary to control the surface roughness. Controlling the surface roughness affects microhardness as well [6], which will affect the compressive residual stresses. It is observed that both the phenomena are contradictory to each other. Improving one affects the other.
Surface Engineering and Processes
Published in Kenneth C. Ludema, Oyelayo O. Ajayi, Friction, Wear, Lubrication, 2018
Kenneth C. Ludema, Oyelayo O. Ajayi
Some plastic flow processes include the following: 1.Burnishing involves pressing and sliding a hardened sphere or (usually) roller against the surface to be hardened. It is a rather crude process which can leave a severely damaged surface. Lubrication reduces the damage.2.Peening is done either with a heavy tool that strikes and plastically indents a surface, usually repeatedly, or by small particles that are flung against a surface with sufficient momentum to plastically dent the surface. The latter is called shot peening if the particles are metal of the size of ballistic shot. The velocity of shot or other particles may be as high as 35 m/s. It is, therefore, a very noisy and dangerous process.3.Skin pass rolling is done with spheres or (usually) rollers of a diameter and loading such that the surface to be hardened is plastically indented to a small depth. Large rolls will plastically deform thin plate or sheet throughout the thickness, but skin pass rolling can be controlled to plastically deform to shallow depths.
Fatigue Life Improvement
Published in Eliahu Zahavi, Vladimir Torbilo, Fatigue Design, 2019
Eliahu Zahavi, Vladimir Torbilo
In summary, burnishing is being applied as a cold-working finishing operation to a wide range of machine parts, such as shafts, bars, pistons, sleeves, cylinders, and others. Usually these parts are manufactured from heat-treated carbon and alloy steels and are ground or finely turned before burnishing. Burnishing then ensures high surface integrity parameters and high endurance, reliability and long fatigue life. Table 7.11 presents test data which confirms the advantage of burnishing as a finishing process after fine turning and grinding.
Investigation of TiAlN coated roller burnishing on Al-(B4C)p MMC workpiece material
Published in Materials and Manufacturing Processes, 2018
E. Shankar, S. Balasivanandha Prabu, T. Sampath Kumar, M. R. Stalin John
During burnishing, the hard tool presses and plastically deforms the work surface without the formation of a chip. The material from the surface peaks flows into the valleys and enhances the surface finish. A few advantages of burnishing surfaces include wear resistance, fatigue strength, corrosion resistance, compressive stress increase and enhanced hardness and surface finish.[101112131415] It further avoids the necessity for super finishing operations like lapping, honing, grinding, etc. Other advantages of the burnishing operation involve no material waste (chip less operation), noise less operation, minimum lubrication requirement, and short cycle time and set up time.
Effect of burnishing on Inconel 718 workpiece surface heated by infrared radiation
Published in Materials and Manufacturing Processes, 2021
Samuel José Casarin, Luiz Eduardo De Angelo Sanchez, Eduardo Carlos Bianchi, Vicente Luiz Scalon, Renan Luis Fragelli, Eduardo Luiz De Godoi, Maria Da Penha Cindra Fonseca
Burnishing is essentially a mechanical process aimed at improving the surface finish[1–4] and mechanical properties of metal workpiece resulting from plastic deformation of its outer layer promoted by the passage of a tool harder than the workpiece along its surface, thus without material removal.[5] The tool, which can have a spherical or roller shape, flow the material from the asperity peaks left by the previous machining process toward the valleys, thus filling them and making the surface more regular. Simultaneously, the surface and subsurface layer of the workpiece is strain hardened, inducing residual compression stresses, which are beneficial for increased fatigue life, wear resistance and corrosion.[6,7]
A review on severe plastic deformation based post-processes for metal additive manufactured complex features
Published in Materials and Manufacturing Processes, 2023
S.M. Basha, N. Venkaiah, T.S. Srivatsan, M.R. Sankar
Burnishing improves surface characteristics by using a unique tool with rollers or spherical balls. Unlike finish turning and milling, burnishing is often used to enhance the surface topography, microhardness, and fatigue life of a component by cold working rather than removing the material.[21,22] In this process, the burnishing tool is made to rotate on the surface of the component using a normal load. This is shown in Fig. 2(a). The load on the roller/ball is applied directly by the tool casing, a hydrostatic force, or mechanical means.[28] Under the influence of an applied load, the surface peaks of the component are plastically deformed or cold-worked as a consequence of the motion of the roller/ball.[29,30] This is shown in Fig. 2(b). This cold working results in the generation of compressive residual stresses in the component with a concomitant increase in the hardness,[29] corrosion resistance,[31] wear resistance,[22] and fatigue life.[32] This process can be performed on a conventional lathe or vertical milling machine by holding the burnishing tool either in a tool post or in a spindle, depending on the overall complexity of the chosen component. The efficiency of the burnishing process depends on the following: Roller/ball diameter,Normal pressure,Burnishing speed, andHardness of the workpiece.