CAD and FEM Modelling of Theoretical Roughness in Diamond Burnishing

Csaba Felhő,Gyula Varga

doi:10.1007/s12541-022-00622-5

Abstract

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.

Highlights

Diamond burnishing is a versatile plastic deformation-based machining method which can be used for several purposes
The conducted investigations are essentially concluded that the CAD modelling method combined with the Hertz theory calculation seems to be a good approximation of the burnishing process, or at least it is not significantly worse, than the applied FEM method
In the case of the roughness parameter Ra, the results obtained with increasing the feedrate became more and more close to the real roughness values

Summary

Introduction

Diamond burnishing is a versatile plastic deformation-based machining method which can be used for several purposes. There are essentially two different types of burnishing: slide burnishing [9] (or diamond burnishing) and roller burnishing [10]. The choosing from these two methods sometimes is not easy,. To investigate the effects of the diamond burnishing process on the machined surface, it is essential to examine the generated surface roughness, which allows for the performance qualification of the respective process. The tool has a defined edge geometry, which allows for the analytical calculation of the theoretical surface profile, which is not that easy in case of abrasive processes, like grinding [19]

Methods

Results

Conclusion