Roller Burnishing Process Research Articles

An optimisation of the internal roller burnishing process for magnesium composites using Taguchi Multi objective optimization method

Machining Metal Matrix Composites with conventional metal removal causes particle debonding and crack propagation. This paper has given enhancing results for magnesium silicon carbide Metal Matrix Composite using an internal roller burnishing process. The optimal process parameters are obtained using a full factorial design and Taguchi Multi Response optimization. The optimized parameters include a spindle speed of 500 rpm, a feed rate of 0.5 mm/rev, and a stock allowance of 0.03 mm. The resulting surface characteristics comprise a surface roughness of 0.1555 µm, an out of roundness of 0.0595 mm, and a surface hardness of 66.9 HV. Scanning electron and atomic force microscope, images analyze the surface topology. Auto parts like transfer case and steering components can use burnished components.

Моделирование и оптимизация процесса накатывания роликом AL6061-T6 для достижения минимального отклонения от круглости, минимальной шероховатости поверхности и повышения ее микротвердости

Introduction. Roller burnishing is one of the most common methods of improving the surface quality of parts, wear resistance, microhardness, and corrosion resistance. The process involves compressing and smoothing the workpiece using the pressure of a hardened roller. It is often used to improve part performance and lifespan in sectors including automotive, aerospace, and medical equipment manufacturing. The literature reviewed shows that the roller burnishing process effectively improves the overall surface quality and hardness of the workpiece. In addition, roller burnishing is considered as an affordable method to enhance the functionality and robustness of machined parts by reducing the likelihood of surface defects such as like scratches and cracks. However, very few studies have been reported on the modeling and optimization of roller burnishing of Al6061-T6 for minimum surface roughness, better microhardness, and roundness. The methods of investigation. In the current work, roller burnishing of Al6061-T6 is modeled and optimized for superior microhardness, roundness, and minimal surface roughness. Under dry-cutting conditions, the performance of roller burnishing of Al6061 specimens is assessed in terms of process factors such as cutting speed, feed, and number of passes. Mathematical models to predict the surface roughness, microhardness, and deviation in roundness are developed based on the experimental results. Results and Discussion. The coefficient of correlation for the developed models is found to be close to 0.9, which indicates that it can be reliably used to predict and optimize the roller burnishing of the Al6061-T6. According to this study, the use of the following cutting parameters leads to the lowest variation in roundness (4.282 µm), the better microhardness (119.2 Hv), and the lowest surface roughness (0.802 µm): cutting speed 344 rpm, feed 0.25 mm/rpm and four passes. Further, the study reveals that increasing the number of passes (beyond four) does not significantly improve the surface roughness or microhardness. However, it does lead to a slight increase in the roundness deviation. Therefore, in order to achieve optimal results, it is recommended to use a maximum of four passes during roller burnishing of Al6061 specimens under dry cutting conditions. These results imply that roller burnishing can effectively improve the overall quality and hardness of the workpiece surface. In addition, roller burnishing is considered as an affordable method to increase the functionality and robustness of machined parts by reducing the likelihood of surface defects like scratches and cracks.

Relationship of the roller burnishing process parameters with the surface and subsurface properties of Inconel 718

Relationship of the roller burnishing process parameters with the surface and subsurface properties of Inconel 718

Effect of roller burnishing on the mechanical behavior and surface quality of Ti6Al4V alloy

A low-cost and effective surface treatment technique that has gained popularity recently is roller burnishing. In this procedure, the rolling element is forced against the surface with a specified amount of force, which results in small plastic deformations that reduce surface roughness without removing chips from the surfaces. The method results in a considerable decrease in surface roughness while the material's surface hardness rises. The effects of roller burnishing process parameters (burnishing pressure, number of passes, and feed rate) on Ti6Al4V tensile strength and surface roughness were investigated experimentally in this study. In the study, the burnishing procedure was carried out via a specifically created disc-shaped equipment using the Taguchi L16 experimental design approach. The study's findings showed that the roller burnishing technique improved the Ti6Al4V alloy's surface quality, microhardness and ultimate tensile strength. It was shown that roller burnishing increased the surface roughness, microhardness and ultimate tensile strength by 64%, 16,25%, and 94%, respectively.

Application of Taguchi Technique to Study Tribological Properties of Roller-Burnished 36CrNiMo4 Steel

The purpose of this work was to study the effect of roller burnishing process on tribological properties of 36CrNiMo4 steel. The experiments were performed under dry and starved lubrication contact conditions. The influence of selected parameters such as applied load, sliding speed, and sliding distance on the coefficient of friction and wear volume was investigated. The Taguchi technique was used to estimate the parameters significantly affecting the tribological properties. The levels of tested input factors were as follows: applied load—5, 10, and 15 N, sliding speed—0.24, 0.48, and 0.72 m/s, and sliding distance—160, 282, and 404 m. The results revealed that load was the most dominating factor that affects the wear volume and the coefficient of friction. The influence of other input factors was smaller. Regression analysis was also performed to predict tribological behavior. The results demonstrated good agreement between experimental and predicted results. The worn-out samples were analyzed using SEM to reveal the wear mechanism.

The Effect of Copper Microstructure on the Surface Characteristics in Roller Burnishing Process

The Effect of Copper Microstructure on the Surface Characteristics in Roller Burnishing Process

Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes

Roller burnishing represents an economical alternative to conventional surface-finishing processes, such as fine turning or honing. In contrast to the well-known wear mechanisms of chip-forming processes, the wear behavior in roller-burnishing is strongly based on the experience of the machine operators. The nature of the finishing process makes roller-burnishing very sensitive to surface defects, as it is often not possible to rework the last step in a process chain. In the present work, a prototype for a smart roller-burnishing tool with 5G communication is presented, which serves as an inline-monitoring tool to detect tool wear. A suitable metric to monitor the tool wear of the manufacturing roll is suggested, and the potentials of 5G communication for the described use-case are evaluated. Based on the signal-to-noise ratio of the process-force, a metric is found that distinguishes new rolls from worn rolls with very small defects on the micrometer scale. Using the presented approach, it was possible to distinguish the signal-to-noise ratio of a roll with very small wear marks by 3.8% on average. In the case of stronger wear marks, on the order of 20 µm, the difference increased to up to 15.6%.

A study on the effect of the roller burnishing process on the axial fatigue performance and surface integrity of AISI 4340 steel

A study on the effect of the roller burnishing process on the axial fatigue performance and surface integrity of AISI 4340 steel

Investigation and Optimization of MQL System Parameters in the Roller-Burnishing Process of Hardened Steel

In the current study, the internal burnishing process under the minimum quantity lubrication (MQL) condition has been optimized to decrease the cylindricity (CYL) and circularity (CIC) of the burnished hole, while the surface roughness (SR) is predefined as a constraint. The optimizing inputs are the diameter of the spray nozzle (D), the spray elevation angle (A), the lubricant quantity (Q), and the pressure value of the compressed air (P). The artificial neural network (ANN) models of burnishing performances are proposed to optimise inputs. The grey relational analysis (GRA) is utilized to compute the weight value of each response. Optimal values of MQL system parameters and technological objectives are selected with the aid of an evolution algorithm (vibration and communication particle swarm optimization (VCPSO) algorithm). The results indicated that the optimal outcomes of the D, A, Q, and P are 1.5 mm, 50 deg, 140 ml/h, and 0.6 MPa, respectively. Furthermore, the CYL, CIC, and SR were decreased by 53.14 %, 57.83 %, and 72.97 %, respectively, at the optimal solution. Finally, the obtained results are expected to be a significant solution to support the machine operator in selecting the optimal MQL system parameters to improve the hole quality in the MQL-assisted burnishing process.

Analysis of Factors Influence on the Efficiency of the Burnishing Rolling Process

Abstract Burnishing is a cold processing process that produces a good quality of the surface by the planetary motion of rolls hardened on turned or perforated surfaces. The result is a mirror surface with high wear and corrosion resistance, the surface of the part depends on several factors such as: ductility of the material, tensile strength, roughness of the workpiece surface before rolling, diameter and shape of the rollers (https://sinotech.com/resources/). Burnishing is the most suitable process to improve the fatigue resistance of dynamically requested parts. Because cold rolling does not remove material, then only the surface roughness rolls, influences the obtained roughness. That is why the roughness of the rolls will be equal to the roughness of the part. The cold rolling finishing method does not require the use of special machines, they can be used existing machines in the production sections such as: milling machines, lathes, drilling machines, lathes with numerical control (https://en.wikipedia.org/wiki/).

Enhancing Surface Integrity of Additively Manufactured Inconel 718 by Roller Burnishing Process

This work presents the effect of burnishing process including burnishing force, burnishing speed and burnishing conditions on surface properties of Inconel 718 alloy fabricated by laser powder based fusion additive manufacturing. As-built, sand blasted and heat-treated specimens are burnished and final surface properties such as surface roughness, surface topography, and microhardness are presented. The performance of the burnished surface is tested through wear test. This study reveals that burnishing process makes substantial contribution to reduce surface roughness of additively manufactured Inconel 718 alloy. Moreover, surface hardness is notably increased resulting from burnishing process and hence wear resistance of this alloy improved. Wear resistance of as-built specimens was increased by 38% through implementing roller burnishing. Wear resistance of heat-treated specimens is increased by 55% through implementing roller burnishing process.

Experimental and Numerical Analysis of the Depth of the Strengthened Layer on Shafts Resulting from Roller Burnishing with Roller Braking Moment.

The article presents the results of investigations into the depth of the plastically deformed surface layer in the roller burnishing process. The investigation was carried out in order to obtain information on the dependence relationship between the depth of plastic deformation, the pressure on the roller and the braking torque. The research was carried out according to the original method developed by the authors, in which the depth of plastic deformation is increased by applying a braking torque to the burnishing roller. In this method, it is possible to significantly increase (up to 20%) the depth of plastic deformation of the surface layer. The tests were carried out on a specially designed device on which the braking torque can be set and the force of the rolling resistance of the roller during burnishing can be measured. The tests were carried out on specimens made of C45 heat-treatable carbon steel. The dependence of the depth of the plastically deformed surface layer was determined for a given pressure force and variable braking moments. The depth of the plastically deformed layer was measured on the deformed end face of the ring-shaped samples. The microhardness in the sample cross-section and the evolution of the microstructure were both analysed.

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Effect of burnishing on Inconel 718 workpiece surface heated by infrared radiation

ABSTRACT Roller burnishing process is a post-machining surface finishing technique that has an advantage over other finishing processes, such as shot blasting or abrasive-tooling processes, because of its simplicity and excellent results (both improved surface finish and improving the mechanical properties of the material). Roller burnishing allows you to eliminate the part grinding step. Nickel super alloys, in turn, including the Inconel 718 have wide application in the aerospace industry due to their high fatigue strength and their ability to work at elevated temperatures. The Inconel 718 shows a predominantly austenitic matrix (γ phase), which under the burnishing process trends to produce an increase in hardness and residual stress. This paper is the result of research on the influence of the conventional roller rolling process at room temperature and at 310°C on a turned part of Inconel 718. Results of surface roughness, roundness deviation, microhardness, residual stress, and deformation of the material under a load of 850 N were analyzed. The obtained results prove the improvement of the material properties after the roller burnishing process: lower values of surface roughness, higher roundness deviation in conventional burnishing, higher surface hardness and higher compressive residual stress in hot burnished specimen.

Optimization of the Internal Roller Burnishing Process for Energy Reduction and Surface Properties

Improving the surface quality after burnishing operation has been the subject of various published investigations. Unfortunately, the trade-off analysis between the energy consumption and surface characteristics of the internal burnishing has been not addressed due to the expensive cost and huge efforts required. The objective of the present work is to optimize burnishing factors, including the spindle speed, burnishing feed, depth of penetration, and the number of rollers for minimizing the energy consumed in the burnishing time, as well as surface roughness and maximizing Rockwell hardness. An adaptive neuro-based-fuzzy inference system (ANFIS) was used to develop burnishing objectives in terms of machining parameters. The optimization outcomes were selected using an evolution algorithm, specifically the non-dominated sorting particle swarm optimization (NSPSO). The results of the proposed ANFIS models are significant and can be employed to predict response values in industrial applications. The optimization technique comprising the ANFIS and NOPSO is a powerful approach to model burnishing performances and select optimal parameters as compared to the trial and error method as well as operator experience. Finally, the optimal solution can help to achieve the improvements in the energy consumed by 16.3 %, surface roughness by 24.3 %, and Rockwell hardness by 4.0 %, as compared to the common values.

Effect of Number of Passes on Surface Properties of Burnished Aluminium Alloy

Basically, roller burnishing process is one of the surface finishing processes. In this process, a hard and highly polished roller will be pressed against a rotating specimen, this causes plastic flow on specimen surface from the peaks of surface irregularities into the valleys, which results in a reduction in the surface roughness considerably. This is a type of cold working whichalso results in improvementof micro-hardness, refinement of microstructure on the surface of the specimen under consideration. This work aims to understand the versatility of roller burnishing processand to understand the effect of the number of burnishing passes to enhance surface properties. Surfaceroughness, electrical conductivityand microhardness were studied in the present work. Experimental work was done on aluminium AA7075-T6 alloy. The parameters under which the burnishing was done were burnishing force, spindle feed and speed and are kept constant in the present work.

Finite element and experimental study of the residual stresses in 2024-T3 Al alloy treated via single toroidal roller burnishing

This article presents the outcomes of finite element (FE) simulations and X-ray stress measurements of residual stresses in high-strength 2024-T3 Al alloy introduced via the single toroidal roller burnishing (STRB) process. In terms of the deforming toroidal roller geometry, STRB is particularly suitable for deep rolling. A 3D FE model was developed using the flow stress concept, and the actual STRB kinematics was simulated to evaluate both hoop and axial residual stresses. The FE model was validated through a comparison of FE and X-ray residual stress distributions. The effects of the burnishing force, feed rate, and number of passes on the residual hoop and axial stresses were studied. It was established that increasing the feed rate leads to a decrease in the residual hoop stresses and an increase in the residual axial stresses. The greater burnishing force increases the compressive zone depth and only slightly increases the surface residual stresses. The FE and X-ray stress analyses confirm the effectiveness of STRB of 2024-T3 Al alloy to introduce significant residual compressive axial and hoop stresses.

Researches and Simulation of Elastic Recovery Phenomena during Roller Burnishing Process of Macro-Asperities of Surface.

The paper presents preliminary studies of a new innovative surface treatment method—the process of roller burnishing of macro-irregularities of the surface. As part of the work, the possibility of plastic shaping of the surface macrostructure with indentations (plateau structure), which will show anti-wear properties through appropriate surface shaping and the compressive stress state in the product’s top layer, was investigated. The essence of the paper is the analysis of one of the aspects of the application of this processing method, i.e., the influence of the elastic recovery of the product on its technological quality measured by dimensional deviation. The main objective of the work is to develop adequate methods and mathematical models to enable the design of the macro-asperities of the surface burnishing process to maintain the dimensional tolerance of the shaped parts. The results of dependencies of elastic recovery of the asperities and the deviation of height, Δht, for sample depths of burnishing were presented. The model tests of the elastic recovery of the model material using the visioplasticity method show that with the increase of the value of the vertical surface asperities, the value of the elastic recovery of the material decreases. The increase of the deviation of the asperities’ height causes a decrease in the value of elastic recovery. With the increase of the value of the vertical angle of the surface roughness, the value of the elastic recovery of the material is smaller.

Plastic flow behavior for machined surface material Ti-6Al-4V with rotary ultrasonic burnishing

A hybrid machining technology with rotary ultrasonic roller burnishing process has been developed. There is no material removal when the machined surface is generated by the hybrid ultrasonic burnishing as comparing with other conventional cutting processes. The kinematic mechanism for plastic flow during surface generation in hybrid rotary ultrasonic burnishing Ti-6Al-4V with cylindrical roller tool was revealed in this paper. Firstly, the machining experiments were carried out for surface generation with hybrid rotary ultrasonic burnishing Ti-6Al-4V. Then, the experimental analysis was conducted and it showed that, there was little change in dimension of the rotary ultrasonic roller burnished workpiece compared to that of milled workpiece. Finally, a 3D finite element (FE) model was proposed to simulate the surface generation in hybrid rotary ultrasonic roller burnishing process. Three machining zones including pile-up deformation area, tensile deformation area, and compressive deformation area were selected for the analysis of the material plastic flow. It was found that the surface generated by rotary ultrasonic burnishing was mainly attributed to the plastic flow of material in these three deformation zones. The FE simulation results showed good agreements with the experimental ones. The proposed research results are helpful for the analysis and diagnosis of the surface generation in ultrasonic burnishing process.

Experimental and numerical study of the subsurface deformation and residual stress during the roller burnishing process

Abstract Roller burnishing process is being extensively used to enhance the fatigue life of the aircraft engine components by introducing compressive residual stress and work hardening. The temperature rise during the burnishing process could be neglected due to the low friction rolling contact between the roller and workpiece, thus simplifying it an elastoplastic deformation process. In this paper, the digital image correlation technique was adopted to obtain the subsurface deformation field during the roller burnishing process. A 3D finite element model was built up to simulate the burnishing process. The predicted surface integrity parameters including subsurface deformation and residual stress are compared with the experimental measurements.