Finite element analysis of ball burnishing process: comparisons between numerical results and experiments

Abstract

Ball burnishing is a surface enhancement process where a residual compressive stress is created in the surface layers of the workpiece. Several studies have been con- ducted on this process, but they are more concerned with the experimental aspect. So, there is still a real need for reliable numerical models that enable us to understand the mechanical behaviour of the workpiece during the process. These models also serve to optimise the studied process. Two-dimensional and three-dimensional finite element (FE) ball burnishing modelling is presented in this paper, where an elastic-plastic material model is assumed in the framework of the FE analysis. The pertinence of these models to predict residual stresses created by the process is discussed by draw- ing comparisons between simulation results and experimental data. The obtained results show that the three-dimensional FE model predicts the residual stresses and provides useful in- formation on the effect of the process parameters.