Modelling of surface formation mechanism during burnishing of aluminium

Stöckmann, Rico; Pütz, Matthias

doi:10.1016/j.procir.2019.04.033

Cited by 5 publications

(6 citation statements)

References 8 publications

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“…Figure 1 shows the modeling procedure. This is similar to the three-step iteration procedure introduced by Röttger in [43] and used by many others, e.g., Stöckmann and Putz [44] and Sartkulvanich et al [20]. This process consists of the following main steps:…”

Section: Methodsmentioning

confidence: 96%

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2D FEM Investigation of Residual Stress in Diamond Burnishing

Felhő

Varga

2022

JMMP

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Sliding friction diamond burnishing is a finishing machining operation whose purpose is to improve the surface integrity of previously machined surfaces and increase their surface hardness. When analyzing a complex process involving plastic deformation, friction, and the interaction between solids, finite element models (FEMs) involve a significant amount of simplification. The aim of this study is to investigate a 2D FEM of the residual stress occurring during diamond burnishing. Before burnishing, the samples were processed by fine turning. Based on the simulations and laboratory experiments performed, it can be concluded that the diamond burnishing process can be modeled with relatively good approximation using two-dimensional modeling. It was also concluded that it is important to consider the initial surface topography in two-dimensional tests. The results indicate that the diamond burnishing process improved the residual stress properties of EN 1.4301 austenitic stainless steel by creating relatively high compressive stress, whose magnitude was between 629 and 1138 MPa depending on the applied force. However, the stress distribution is not uniform; it is mostly concentrated under the roughness peaks.

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Section: Methodsmentioning

confidence: 96%

“…Although Röttger originally recommended at least four ball impressions for the simulation, recent research [11,20,44] has shown that it is more appropriate to simulate more steps, at least eight. Therefore, eight steps were used in the present research.…”

Section: Methodsmentioning

confidence: 99%

2D FEM Investigation of Residual Stress in Diamond Burnishing

Felhő

Varga

2022

JMMP

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“…This modeling method has already been used by many researchers with good results: e.g. Stöckmann and Putz [38] have applied this method for flat surfaces, while John et al [39] has used it for turning. This is an approximate simulation of the burnishing process, but-according to the referenced works-seems to be adequate for 2D roughness calculations.…”

Section: Finite Element Modelling Of Surface Roughness In Diamond Bur...mentioning

confidence: 99%

CAD and FEM Modelling of Theoretical Roughness in Diamond Burnishing

Felhő

Varga

2022

Int. J. Precis. Eng. Manuf.

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Diamond burnishing is a widely used finishing machining that can have a positive effect on both the roughness of cut surfaces and its stress state. This paper is focused on the examination of the theoretical and real roughness of surfaces machined by sliding burnishing. In determining the theoretical roughness, the surface structure created by the pre-burnishing cutting (turning) was also considered. Two different modelling methods were used to obtain theoretical surface roughness data: CAD-modelling and finite element simulation. A method using CAD-based modelling of the machined surface was used to determine the theoretical roughness for both the turning and burnishing processes. However, this previously developed model is not directly applicable to plastic deformation processes such as diamond burnishing, so the principle of the Hertz theory for normal contact of elastic solids was used to calculate the penetration depth of the tool into the workpiece. The 2D FEM simulations were performed in the DEFORM software. To validate the applied modelling methods, real cutting experiments were performed, where the surface roughness values were measured during diamond burnishing experiments with different feed per revolution values. Based on the comparison of both applied modelling methods with real roughness data it can be stated that the theoretical roughness values are well approximated the real data.

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“…The plastic deformation of the part's surface layer can effectively improve the surface roughness and surface hardness of rolled part. Meanwhile, the rolling process can make compressive stress in a part's surface layer-i.e., residual compressive stress-which can directly increase the fatigue strength and fatigue life of rolled part [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

“…Coatings 2019, 9, x FOR PEER REVIEW 2 of 11 roughness and surface hardness of rolled part. Meanwhile, the rolling process can make compressive stress in a part's surface layer-i.e., residual compressive stress-which can directly increase the fatigue strength and fatigue life of rolled part [4][5][6]. Surface rolling strengthening technology was initially mainly used for surface strengthening of low carbon steel, alloy steel, pure aluminum, brass, and other metal materials in the 20th century.…”

Section: Introductionmentioning

confidence: 99%

Research on Mechanical Properties of 210Cr12 Shaft Surface Processed with Rolling

Qiao

Chen

et al. 2020

Coatings

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The rolling process is one of the most effective ways for strengthening a part’s surface. As the press force exerted on specimen in rolling process, material in the surface layer will deform plastically if the press force is sufficient. That might result in grain refinement, dislocation configuration change, or phase change in specimen surface layer material. Consequently, the surface material mechanical properties can be changed. The effects of rolling parameters on surface residual stress, micro-hardness, and surface roughness for a 210Cr12 shaft have been investigated. After the rolling process, the surface residual stress of the specimen changes from tensile stress to compressive stress, and a stable residual compressive stress layer is formed. The maximum absolute value of compressive stress can be up to 216MPa. With the increase of the value of contact stress exerted on shaft surface and the number of rolling cycles, the absolute value of residual compressive stress increases firstly and then becomes stable. With the increase of depth from shaft surface to interior, the absolute value of residual compressive stress increases initially, then decreases and disappears finally. The maximum absolute value of residual compressive stress exists at the position beneath specimen surface about 0.025mm. The depth of residual stress layer is about 0.2 mm. Research results indicate that shaft surface microhardness can be improved within small range, surface roughness can be reduced up to 67%.

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Modelling of surface formation mechanism during burnishing of aluminium

Cited by 5 publications

References 8 publications

2D FEM Investigation of Residual Stress in Diamond Burnishing

2D FEM Investigation of Residual Stress in Diamond Burnishing

CAD and FEM Modelling of Theoretical Roughness in Diamond Burnishing

Research on Mechanical Properties of 210Cr12 Shaft Surface Processed with Rolling

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