Modelling of the ball burnishing process with a high-stiffness tool

Abstract

This paper deals with the problem of forming a surface roughness profile of a machined surface and a definition of the optimal depth of penetration in ball burnishing which would allow minimization of surface roughness. The assumptions, which have been numerically and experimentally verified, claim that maximum surface quality, i.e., minimum surface roughness, Ra, is achieved when the depth of ball penetration into the workpiece material is approximately equal to the maximum peak height, Rp. For the purpose of numerical simulations, a surface roughness model based on milling kinematics was used. Numerical simulations and the used roughness model support the claim that penetrating with a stiff tool up to the mean line of the roughness profile yields best surface quality. The authors maintain that ball penetrations, which exceed Rp, cannot significantly improve surface quality. Furthermore, the phenomenon of profile peak deformation is substantially clarified. The analysis of internal stresses within the workpiece after ball burnishing allowed a relationship to be established between internal stress distribution along the depth of the hardened layer and ball penetration depth.

Analysis of Surface Geometry Changes after Hybrid Milling and Burnishing by Ceramic Ball

“…Research papers and industrial practice focus on the combination of machining types [1,2,3,4,5,6,7,8,9], including turning [10], milling [11,12,13,14,15], drilling, and threading, using machining centers with forming processes like burnishing [1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,18]. The main aim of the new technology is to meet the smoothness and strength requirements of the surfaces of the part [1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,18,19,20,21]. The optimization of the technological parameters of turning [10] or milling [5,6] makes it possible to obtain a satisfactory surface geometry (with low roughness and a useful Abbott–Firestone curve).…”

An analytical model of burnishing forces using slab method

“…It causes microstructure refinement and improvement in the mechanical properties and fatigue life. 1…”

Investigation of ball burnishing processing on mechanical characteristics of wooden elements

“…3,7 Randjelovic et al. 3 used FEA and an experiment to demonstrate that the initial surface roughness has no significant effect on the surface quality achieved by ball burnishing. Tadic et al.…”

“…Burnishing is a cold finishing process and no-chip process that applies a sufficient force over the yield strength of materials to produce plastic deformation of a surface layer, in which a roller or a ball pushes surface materials from the peaks into the valleys; thus the asperities are flattened. [1][2][3][4][5][6] Many previous investigations of burnishing processes have been focused on the ball burnishing process, due to its advantages. 3,7 Randjelovic et al 3 used FEA and an experiment to demonstrate that the initial surface roughness has no significant effect on the surface quality achieved by ball burnishing.…”

“…[1][2][3][4][5][6] Many previous investigations of burnishing processes have been focused on the ball burnishing process, due to its advantages. 3,7 Randjelovic et al 3 used FEA and an experiment to demonstrate that the initial surface roughness has no significant effect on the surface quality achieved by ball burnishing. Tadic et al 4 analysed the influence of ball burnishing tool stiffness on surface roughness.…”