Abstract
This article demonstrates a multi-step process for forming a nominally flat surface with circumferential lubricating microcavities on a tribological assembly of an Х38CrSi steel shaft. The process includes finish turning, preliminary strengthening burnishing, deformation profiling of microcavities by a honing stone and smoothing of microprotrusions. The study determines the optimal technological parameters for each of the transitions based on microhardness and oil absorption power maximization, as well as roughness and periodic impact minimization. The process optimization is conducted using the Tagichi experiment design method. The optimal combination of technological parameters for hardening burnishing was discovered to be: normal force F = 200 N; feed rate f = 0.025 mm/rev and three tool passes. These burnishing parameters practically eliminate the influence of periodic impacts at spatial frequencies determined by the tool feed rate and the number of spindle rotations during turning. We determined suitable honing stone grit parameters and application force that yield microcavities 3.8 to 8.1 μm in depth, as well as the optimal parameters for smoothing of microprotrusions, resulting in a bearing area roughness of Sa = 0.15 µm and oil absorption power of 13.74×10–5 mm3/mm2.
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