Finite element analysis of ball burnishing process: comparisons between numerical results and experiments

Ball burnishing is a surface enhancement process where a residual compressive stress is created in the surface layers of the workpiece. Several studies have been conducted on this process, but they are more concerned with the experimental aspect. So, there is still a real need for reliable numerical models that enable us to understand the mechanical behaviour of the workpiece during the process. These models also serve to optimise the studied process. Two-dimensional and three-dimensional finite element (FE) ball burnishing modelling is presented in this paper, where an elastic–plastic material model is assumed in the framework of the FE analysis. The pertinence of these models to predict residual stresses created by the process is discussed by drawing comparisons between simulation results and experimental data. The obtained results show that the three-dimensional FE model predicts the residual stresses and provides useful information on the effect of the process parameters.