Abstract
Burnishing is an effective chipless finishing process for improving workpiece properties: hardness, vibration resistance and surface quality. The application of this technology is limited to rotationally symmetrical structures of deformable metals. Because of the multiaxial characteristics, the transfer of this force controlled technology on to prismatic shapes requires a comprehensive process development. The main purpose of this paper is the characterization of a plain burnishing process on aluminium EN AW 2007 with a linear moved, spherical diamond tool. The method of design of experiments was used to investigate the influence of different machined surfaces in conjunction with process parameters: burnishing force, burnishing direction, path distance and burnishing speed. FEM simulation was utilized for strain and stress analysis. The experiments show, that unlike the process parameters the initial surface roughness as 3rd order shape deviation does not have a significant influence on the finished surface. Furthermore a completely new surface is created by the process, with properties independent from the initial surface roughness.
Highlights
Burnishing is a force controlled forming process, which is widely applied on finishing of rotationally symmetrical parts e.g. found in the automotive industry
The experimental investigation and the numerical analysis of burnishing of EN AW 2007 show that the burnishing direction and surface structure before burnishing have no significant influence on the burnishing process and the investigated surface parameters, especially for such ductile materials like aluminium
The investigation at the surface border area of the process shows that the material forms a constant bead in front of the tool. This behaviour leads to the forming of a new surface, with roughness values manly depending on the burnishing feed
Summary
Burnishing is a force controlled forming process, which is widely applied on finishing of rotationally symmetrical parts e.g. found in the automotive industry. A burnishing tool is pressed under a force onto the workpiece surface for this finishing process. At the same time an increase in compressive residual stress at the boundary layer is achieved, which leads to an increase of surface hardness and strength [2]. With this procedure a surface quality similar to the results after grinding for ductile materials can be reached [3]. A variety of different surface structures, which are only limited by the geometry of the burnishing tool and the machine kinematics, can be processed
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