Finite element analysis of ball burnishing for large flat surface: Comparisons between experimental and numerical results

Abstract

A three-dimensional (3D) finite-element (FE) based-model is developed for ball-burnishing in which an elastic–plastic material model is anticipated in the FE analysis framework. The model is used for better analysis of the experimental results when processing large flat surfaces and provides insights into the optimization of burnishing parameters. In this study, normal preload of 300 N, applied to the ball, is kept constant during the simulation. This case obtained in a previous work, was the optimal value which yielding a best surface quality of AISI 1010 steel plates. The numerical simulation results (residual stresses, plastic strain) will be extracted when the tool penetration will be stable, and a homogeneous treated area will be formed. Under the same ball burnishing conditions, the distributions of residual stresses (in feed direction and in cross-feed direction) from 3D simulations will be shown and compared with X-ray findings. In addition, the effect of number of passes on the finite element results has been studied. It is shown that a second pass of the ball on the burnished surface increases considerably these stresses and the strain in the surface layer. Preliminary results obtained from the confrontation of the distribution of residual stresses induced by mechanical treatment of AISI 1010 steel plates indicate good agreement between the experimental and FE results.