Surface Hardening of High-Strength Low Alloy Steels (HSLA) Dual-Phase Steels by Ball Burnishing Using Factorial Design

Burnishing is used increasingly as a finishing operation which gives additional advantages such as increased hardness, fatigue strength, and wear resistance. Experimental work based on 3⁴ factorial design was carried out to establish the effects of ball burnishing parameters on the surface hardness of high-strength low alloy steels (HSLA) dual-phase (DP) steel specimens. Statistical analysis of the results shows that the speed, feed, lubricant and ball diameter have significant effect on surface hardness.     

滚挤压加工对颗粒增强金属基复合材料表面粗糙度的影响

将滚挤压加工工艺引入到颗粒增强铁基复合材料的精加工领域,得出了各工艺参数、增强相含量等因素对表面粗糙度的影响规律,分析了这种复合材料的滚挤压加工机理,并优化了工艺条件.     

Investigation of TiAlN coated roller burnishing on Al-(B4C)p MMC workpiece material

Burnishing avoids the need for super finishing operations after the conventional turning process, to enhance the surface quality. This paper deals with the surface modifications of Al(B₄C)_p Metal Matrix Composites (MMC) workpiece material after burnishing with a TiAlN coated WC roller. The burnishing speed, lubrication type, burnishing passes, and coating were the input parameters. Surface hardness and roughness after the burnishing were studied. It was found that the coating on the WC roller had enhanced the hardness in the workpiece after burnishing in the case of Al-5?wt.% (B₄C)_p, under all conditions. The effect of the coating on the work piece surface hardness was not significant with Al-10?wt.% (B₄C)_p. While burnishing Al-5?wt.% (B₄C)_p, the minimum surface roughness combined with maximum surface hardness was obtained, during the third pass under dry condition using uncoated rollers. The number of passes to achieve the desired surface conditions reduced, on using coated rollers with kerosene as the lubricant.     

Optimization of interior roller burnishing process for improving surface quality

Improving the surface characteristics of roller burnishing processes is one of effective approaches to decrease the machining costs and time. This paper systematically investigates the nonlinear relationships between machining parameters and surface characteristics, including surface roughness (R_a), surface hardness (H), and hardness depth (HD) of the interior roller burnishing using response surface method (RSM) model. Three process parameters considered include spindle speed S, feed rate F, and burnishing depth D. A set of physical experiments was carried out with AISI 1045 steel on a computer numerical control (CNC) milling machine using the roller burnishing tool. The target of the current complex optimization is to enhance the surface hardness and hardness depth, while the surface roughness is considered as the constraint. Finally, an evolutionary algorithm entitled archive-based micro genetic algorithm (AMGA) was used to generate a set of feasible optimal solutions and determine the best machining conditions. The results show that an appropriate trade-off solution can be drawn with regard to the low surface roughness and high the surface hardness as well as hardness depth. Furthermore, the integration of RSM model and AMGA can be considered as a powerful approach for modeling and optimizing interior roller burnishing processes.     

混粉电火花加工在模具制造中的应用

通过对混粉电火花加工工艺与传统模具制造工艺的比较，从混粉电火花加工工艺的机理、表面特性、影响因素等各方面来阐述，混粉电火花加工是生产高精度、高寿命、效率的模具的最有效的工艺之一。     

Unique regenerative chatter in wiper-turning operation with burnishing process Part 2: Experimental verification of predicted generation mechanism,critical stability,and characteristics

In this paper, the predicted generation mechanism, chatter stability, and characteristics of the unique regenerative chatter with the burnishing process in wiper-turning operations are verified experimentally. It was found in the first part of the paper that the vibration regenerates in the burnishing process by the wiper part of the insert causing a novel type of chatter. In this second part, this chatter phenomenon is investigated in an experimental manner to verify its mechanism. The specific burnishing force, which is a gain factor characterizing the burnishing process, is determined by the Hertzian contact law. In addition, the specific cutting force is measured by a cutting test, the compliance of the flexible structure is measured by a hammering test, and the residual compliance is measured by a static indentation test. Then, experiments are conducted where the tilt angle and the feed rate are varied to find the critical stability. The conducted chatter experiments prove that the predicted generation mechanism, critical stability, and characteristics are true.     

Investigation of the burnishing process with PCD tool on non-ferrous metals

It is well known that the no-chip machining process, burnishing, can easily improve surface roughness, waviness and hardness. To get the practical useful parameters, the effects of various burnishing parameters (spindle speed, depth, feed, burnishing radius and lathe) on surface roughness and waviness of the non-ferrous components were studied experimentally with a theoretical analysis. The experiments were conducted with a simply designed cylindrical surfaced polycrystalline diamond tool developed by us. It was found that smaller parameters do not mean lower surface roughness or waviness and different optimum burnishing parameters can be got under different burnishing conditions.     

Contact force studies of a burnishing slider

In order to design the flying height of a burnishing slider accurately, the contact force between the burnishing slider and the disk needs to be well evaluated. This paper studies the contact force of a burnishing slider by both experiment and simulation. The experiment is conducted by measuring the acoustic emission signals of the contact force avalanche, and the simulation is based on the self-developed air bearing surface simulation code applying the probability model for the contact force calculation. The influence of contact force on the burnishing effect is discussed. It is observed that the simulation results are well correlated with the experimental measurements. It is believed that the simulation code is capable to design burnishing sliders with reasonable accuracy.     

Friction and wear of MoS2 films on laser textured steel surfaces

Incorporation of solid lubricant into micro-reservoirs produced by Laser Surface Texturing (LST) and its effect on the tribological properties of surfaces under dry friction is studied. The density of the dimple reservoirs and the height of the bulges around them are investigated in terms of the longevity of solid lubricant films burnished on LST steel surfaces. Friction tests were performed using a ball-on-flat device. Optimum density (40-50%) of the dimples is revealed. It is shown that the adhesion of solid lubricant in the space between the dimples is provided by mechanical engagement of particles in the rough surface and by smearing the solid lubricant around the dimples. Best results are obtained with the surfaces that were lapped to half of the height of bulges. Long wear life of burnished film on LST steel surfaces is apparently provided by preservation of thin MoS₂ film around the bulges and by supply of solid lubricant from the dimples to the surface.     

ENHANCEMENT OF SURFACE QUALITY AND TRIBOLOGICAL PROPERTIES USING BALL BURNISHING PROCESS

Surface treatment is an important aspect of all manufacturing processes to impart specific physical, mechanical and tribological properties. Burnishing process is a post-machining operation in which the surface of the workpiece is compressed by the application of a ball or roller to produce a smooth and work-hardened surface by plastic deformation of surface irregularities. In the present study, simple and inexpensive burnishing tools, with interchangeable adapter for ball and roller were designed and fabricated to meet the requirements of the present study. Then, ball burnishing processes were carried out on aluminium 6061 under different parameters and different burnishing orientations to investigate the role of burnishing speed, burnishing force and burnishing tool dimension on the surface qualities and tribological properties. The results showed that burnishing speed of 330 rpm and burnishing force of 160 N produce optimum results. Meanwhile, a decrease in the burnishing ball diameter leads to a considerable improvement in the surface roughness up to 75%. On the other hand, parallel burnishing orientation exhibits lower friction coefficient compared to cross burnishing orientation. Furthermore, ball burnishing process is capable of improving friction coefficient by 48% reduction and weight loss by 60–80% reduction of burnished surface of Aluminum 6061. These findings are further supplemented by the surface features as seen in SEM photomicrographs.