Determination of Optimal Ball-Burnishing Parameters for Plastic Injection Moulding Steel

Chen, C.H.; Shiou, Fang‐Jung

doi:10.1007/s001700300019

Cited by 20 publications

(15 citation statements)

References 14 publications

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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%

“…Requirements that the process engineer faces are hard to be satisfied. The ultimate state of SGS, its texture and height of asperities, depends on the type and kind of tools used and values of technological parameters [1,2,5,6,7,8,9,10], as well as characteristics of the machined material.…”

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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Section: Surface Milling and Burnishingmentioning

confidence: 99%

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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“…In recent years, researchers have frequently used the Taguchi method [14,15], the response surface methodology [2,17], and the fuzzy logic method [16] for the parameters optimization of ball-burnishing process.…”

Section: Introductionmentioning

confidence: 99%

Modeling and optimization of a ball-burnished aluminum alloy flat surface with a crossed strategy based on response surface methodology

Hamdouni¹,

Bouzaiene

Montagne

et al. 2016

Int J Adv Manuf Technol

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. Abstract In this work, a new ball-burnishing strategy, in two crossed passes, was applied on the flat machined surface of 2017A-T451 aluminum alloy to investigate the influence of three classical ball-burnishing factors (burnishing speed V b in mm/min, depth of penetration a b in μm and lateral feed f in mm) on the treated surface integrity enhancement. Experimental work is based on the application of an experimental face-centered composite design (CCD) formed by three factors at three levels. The mathematical modeling of the average roughness Ra, of the mean spacing of roughness profile irregularities Sm and of the surface hardness HIT of the treated surfaces was performed by the response surface methodology (RSM). Best ball-burnished surface integrity has been established by the application of optimal ballburnishing studied factors (V b = 500 mm/min, a b = 40 µm, and f = 0.2 mm). High surface quality is then characterized by a gain in average roughness Ra of 81 %, an enhancement in the mean spacing of profile irregularities Sm of 34 % and an improvement in surface nano-hardness HIT of 17 % when compared to the machined surface. Machined and ballburnished optimized surface characterization confirms surface finishing process power and contribution to surface integrity enhancement of treated flat surface.

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“…Plastic flow of the original asperities occurs when the yield point of the specimen's material is exceeded [10]; consequently the asperities will be flattened. Burnishing process has many advantages over the other finishing processes, the improvement of the surface roughness through the burnishing process generally ranged between 40% and 90% [11][12][13]. Compressive stresses are also induced in the surface layer, giving several improvements to mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

Study the influence of a new ball burnishing technique on the surface roughness of AISI 1018 low carbon steel

Ibrahim

Khalil

Tawfeek

2015

IJET

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Hard roller burnishing with a ball tool is a surface-finishing where a free-rotating tool rolls over the machined surface under high pressures and flattens the surface roughness peaks by cold work. In the present work, a new burnishing technique has been applied which enables both single and double ball burnishing process in site after turning without releasing the specimen. Sets of experiments are conducted to investigate the influence of burnishing force, feed, speed and number of tool passes on surface roughness of AISI 1018 Low Carbon Steel specimens. Burnishing results showed significant effectiveness of the new burnishing technique in the process. The results revealed that minimum surface roughness are obtained by applying the double ball burnishing process on AISI 1018 Low Carbon Steel specimens. Improvement in surface finish can be achieved in both single and double ball burnishing by increasing the number of burnishing tool passes. The results are presented in this paper.

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Determination of Optimal Ball-Burnishing Parameters for Plastic Injection Moulding Steel

Cited by 20 publications

References 14 publications

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

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

Modeling and optimization of a ball-burnished aluminum alloy flat surface with a crossed strategy based on response surface methodology

Study the influence of a new ball burnishing technique on the surface roughness of AISI 1018 low carbon steel

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