Abstract
• The proposed MABB tool can burnish also non-magnetizable and other materials. • Optimal roughness is at steel, aluminium and austenite steel but uncertain at polimer. • 20% hardness increase is at C45 steel and AA7075 aluminium, hardened thickness 0.3 mm. • The various burnishing strategies can increase and also decrease the flatness error. • Cycloid path is a compromise for roughness (micro-level) and flatness (macro-level) The burnishing process is applied to improve the surface roughness and hardness. The goal of the reported research was to evaluate the machining conditions on magnetisable and non-magnetisable materials by the novel permanent magnetic assisted ball burnishing (MABB) tool. The MABB tool was designed to reduce the surface roughness but this process has further effects on the surface C45 steel, X6CrNiTi1811 austenite steel, AA7075 aluminium alloy and PA6 polymer materials were burnished in the experiments. Surface quality is a complex feature that refers to the micro-geometrical characteristics of the machined surface. It includes roughness and waviness and gives a realistic picture about the top layer of the surface, while micro hardness and grains structure are especially important on sub-surface level. Results according to these analysed aspects mirrored that all of the tested materials can be burnished by the novel MABB tool, however, the effects from the economical viewpoints are diverse.
Highlights
The magnetic assisted ball burnishing (MABB) process is one of the cold-plastic finishing processes
The authors of this paper investigated in their former analysis the effects of ball burnishing on C45 steel applying the novel MABB tool [4]
After the burnishing, using all the designed machining parameters on all the various materials, the surfaces were evaluated by measuring the surface hardness, average surface roughness, and by microscopic pictures were taken about the structure of the modified material layer
Summary
The magnetic assisted ball burnishing (MABB) process is one of the cold-plastic finishing processes. During the analysis the tool is continuously cooled internally by minimum quantity lubrication (MQL) oil During this flat surface machining, while the tool moves on the planed path at the given feed rate, at the same time it rotates. In case of ferromagnetic materials, the required burnishing force is provided by the attractiveness of the balls, if the tool approaches the workpiece at a given h distance [5] (Fig. 2). This magnetic force cannot be established on non-magnetizable materials, because the magnetic attraction between the balls and the cone does not allow the balls to rotate, so it results in the deterioration of the surface quality [6]. Inappropriate surfaces can cause failures during usage and the evaluation of failure is a complex process, so the capability of the surface quality in the industrial life is especially important [9,10,11]
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