Abstract
The present research is focused on continuously measuring the variability of the burnishing force during conducting ball-burnishing process for specimens with surfaces with 3D shape, by using CNC milling machine with dual rotary table installed. For measuring the burnishing force and its variability, the specifically developed ball-burnishing tool with miniature force sensor was used. To assess the degree of influence of the main regime parameters on the variability of the burnishing force, the four factors full factorial experiment design with two levels per factor and four replications per run has been carried out. The experimental results are processed statisti-cally and techniques such as Pareto and ANOVA were used after that, for sorting them by degree of significance. Some conclusions about the magnitude and the causes of the obtained variability also are given.
Highlights
It is well known, that implementation of ball-burnishing (BB) or vibratory ball-burnishing (VBB) processes as finishing operations in the processing of machine parts with different macro-shape, leads to some operational improvements such as better surface roughness, increase of the fatigue strength, corrosion and wear resistance, etc
The present research is focused on continuously measuring the variability of the burnishing force during conducting ball-burnishing process for specimens with surfaces with 3D shape, by using CNC milling machine with dual rotary table installed
2.1 Setup for experimental measuring the burnishing force during BB process In Fig. 2, a, b, are shown the basic components of the experimental setup, used for initially adjustment of the nominal values and for measuring the variability of the burnishing force F, [N] during BB processing of complex (3D) surfaces. It is consisting of specially designed deforming ball tool whit integrated miniature force sensor type FCM (Fnom=5 kN) (Slavov & Iliev, 2016, 2017), a vertical CNC milling machine HAAS VF3 with installed dual rotary table type HAAS TR110 on which are fastened test specimens
Summary
That implementation of ball-burnishing (BB) or vibratory ball-burnishing (VBB) processes as finishing operations in the processing of machine parts with different macro-shape, leads to some operational improvements such as better surface roughness, increase of the fatigue strength, corrosion and wear resistance, etc. CNC milling machines that can perform multiaxis simultaneous milling operations are often used for their realization This is necessary because in order to obtain homogeneous qualitative, physical, and mechanical parameters overall complex surface processed by BB or VBB, it is not enough the ball-tool only to travel equidistantly, but its axis of symmetry must always be perpendicular to the momentary curvature of the burnished surface (Apro, 2009). When the burnished surface has 3D macro-shape, the reaction vector R2, [N] constantly changes its angle and direction, depending on the momentary curvature of the complex surface, even when magnitude of the burnishing force F, [N] is constant This will lead to permanent changes in the regime parameters of burnishing operation, which will inevitably have a negative impact on the quality of surface finish
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