Abstract
Several manufacturing processes are used to beneficially influence the surface and subsurface properties of manufactured parts. Different aspects such as the surface topography or resulting residual stresses are addressed using different manufacturing processes. This paper presents the first approach for pulsed mechanical surface treatment (PMST), a new manufacturing process aiming to combine the mechanics used in deep rolling and shot or hammer peening. The process can generate a defined surface topography while constantly impinging a mechanical impact on the workpiece. Two different tools (type 1 and type 2) have been designed to approach this new concept. Hardened carbide pins are used for type 1 to prove the concept using a simpler kinematic and resulting in a burnishing-like process. For type 2, hardened roller is used and results in an actual rolling process. Specimens made of S235 are processed in experiments with tool type 1 with varying pulse frequency and feeds. The resulting surface topography is described using optical measurement systems while micro-hardness measurements are used to describe the subsurface properties. The results in general show an increase of hardness in the surface and subsurface layer while the resulting surface topography can be directly controlled by the process parameters and therefore be designed for specific functional properties.
Highlights
Numerous manufacturing processes like honing, deep rolling, burnishing, or shot peening are used to beneficially influence the surface and subsurface properties of highly stressed parts across different industries such as automotive engineering, aerospace technologies, mechanical engineering, and life science engineering
The results in general show an increase of hardness in the surface and subsurface layer while the resulting surface topography can be directly controlled by the process parameters and be designed for specific functional properties
For example, is used as one of the last processes in the manufacturing chain of cylinder bores in conventional combustion engines, to correct deviations in the cylindrical shape and to generate a functional surface with the potential to hold a specific amount of lubricant [1]
Summary
Numerous manufacturing processes like honing, deep rolling, burnishing, or shot peening are used to beneficially influence the surface and subsurface properties of highly stressed parts across different industries such as automotive engineering, aerospace technologies, mechanical engineering, and life science engineering. For example, is used as one of the last processes in the manufacturing chain of cylinder bores in conventional combustion engines, to correct deviations in the cylindrical shape and to generate a functional surface with the potential to hold a specific amount of lubricant [1]. The process can be adjusted to meet specific requirements for surface roughness, the resulting geometrical shape, and coolant storing volume on honed surfaces. Honing is a specific grinding process, the cooling storing volume is adjustable though the “real” volume can only be statistically determined because of the abrasive tool material [2]. Form-honing is a more advanced concept to generate more complex cylinder shapes compared to conventional honing but is limited to cylindrical shapes [3]
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