Evaluation of Surface Roughness of Aluminum Alloy in Burnishing Process Based on Chaos Theory

Burnishing experiments with different burnishing parameters were performed on a computer numerical control milling machine to characterize the surface roughness of an aluminum alloy during burnishing.The chaos theory was employed to investigate the nonlinear features of the burnishing system.The experimental results show that the power spectrum is broadband and continuous,and the Lyapunov exponentλis positive,proving that burnishing has chaotic characteristics.The chaotic characteristic parameter,the correlation dimension D,is sensitive to the time behavior of the system and is used to establish the corresponding relationship with the surface roughness.The correlation dimension was the largest,when the surface roughness was the smallest.Furthermore,when the correlation dimension curve decreases,the roughness curve increases.The correlation dimension and surface roughness exhibit opposite variation trends.The higher the correlation dimension,the lower the surface roughness.The surface roughness of the aluminum alloy can be characterized online by calculating the correlation dimension during burnishing.

Surface Texture Analysis after Hydrostatic Burnishing on X38CrMoV5-1 Steel

Ball burnishing is a plastic deformation process used as a surface smoothing and surface improvement finishing treatment after turning or milling processes. This process changes the surface stereometrics of the previously machining surface. Burnishing with hydrostatic tools can be easily and effectively used on both conventional and Computer Numeric Control(CNC) machines. The existing research of the burnishing process mainly focuses on the functional surface characterization, for example, surface roughness, wear resistance, surface layer hardness, etc. There is a lack of references reporting a detailed analysis of 3D parameters calculation with a mathematical model to evaluate the results of the ball burnishing. This paper presents the effect of ball burnishing process parameters with hydrostatic tools on the resulting surface structure geometry. The surface topography parameters were calculated using the Taly Map software. Studies were conducted based on Hartley’s static, determined plan. Such a plan can be built on a hypersphere or hypercube. In this work, a hypercube was used. In the case of Hartley’s plan makes it possible to define the regression equation in the form of a polynomial of the second degree. The input process parameters considered in this study include the burnishing rate, applied pressure, and line-to-line pitch. The significant influence of these parameters was confirmed and described as a mathematical power model. The results also showed a positive effect of hydrostatic burnishing on the roughness and geometric structure of the surface.

Investigation of Two-Dimensional Ultrasonic Surface Burnishing Process on 7075-T6 Aluminum

A novel two-dimensional ultrasonic surface burnishing process(2D-USBP)is proposed.7075-T6 aluminum samples are processed by a custom-designed 2D-USBP setup.Parameter optimization of 2D-USBP is conducted to determine the best processing strategy of 7075-T6 aluminum.A uniform design method is utilized to optimize the 2D-USBP process.U〔3(133)and 4(72)tables are established to conduct parameter optimization.Burnishing depth,spindle speed,and feed rate are taken as the control parameters.The surface roughness and Vickers hardness are taken as the evaluation indicators.It establishes the active control models for surface quality.Dry wear tests are conducted to compare the wear-resistance of the 2D-USBP treated sample and the original sample.Results show that the machining quality of 2D-USBP is best under 0.24 mm burnishing depth,5000 r/min spindle speed,and 25 mm/min feed rate.The surface roughness of the sample is reduced from 2517.758 to 50.878 nm,and the hardness of the sample surface is improved from 167 to 252 HV.Under the lower load,the wear mechanism of the 2D-USBP treated sample is mainly abrasive wear accompanied by delamination wear,while the wear mechanism of the original sample is mainly delamination wear.Under the higher load,the accumulation of frictional heat on the sample surface transforms the wear mechanisms of the original and the 2D-USBP treated samples into thermal wear.

An investigation into ball burnishing process of magnesium alloy on CNC lathe using different environments

Ball burnishing routine permits through a simple,fast and economical manner to obtain free chip on the manufactured parts.It generates a superior surface finish by rotating a ball tool against a workpiece.The burnishing process is commonly developed in industry in order to improve the surface quality,which is a critical issue in the manufacturing sector.An experimental study were carried out to determine the best surface quality for magnesium alloy subjected to d iff ere ni medium.Burnishing of magnesium alloy was performed varying four different mediums and combining different burnishing parameters.To design the experiment were used the classical Taguchi method through which were developed the L16 orthogonal array.This strategy allowed to detect the driving parameters that generate the best surface roughness value by computing the signal-to-noise ratio.The driving parameters values for this study are 400 N(force),0.05 mm/min(feed rate),three number of passes and boron oil as medium.The results are paramount important for designing heavy parts used in transportation vehicles such as automobiles,airplanes,high-speed trains etc.

Improvement of Flat Surfaces Quality of Aluminum Alloy 6061-O By A Proposed Trajectory of Ball Burnishing Tool

Burnishing is a profitable process of surface finishing due to its ability to be automated,which makes burnishing method more desirable than other finishing methods.To obtain high surface finish,non-stop operation is required for CNC machine and we can attain that by choosing a suitable trajectory of the finishing tool.In other words,burnishing paths should be multidirectional rather than monotonic,in order to cover uniformly the surface.Indeed,the burnishing force is also a key parameter of the burnishing process because it determines the degree of plastic deformation,and that makes determining the optimum burnishing force an essential step of the burnishing process a success.Therefore,we consider the strategy of ball burnishing path and the burnishing force as variable parameters in this study.In this paper,we propose a new strategy of burnishing tool path with trochoid cycles that achieves a multidirectional burnishing of the surface according to various patterns.Taking into consideration the optimum burnishing force,to improve flat surface finish of AL6061-O samples by reducing the surface roughness parameter(Rz).Experiments carried out on 3-axis milling machine show that the proposed trochoidal path is more effective than the conventional one.

Improvement in Surface Roughness and Hardness for Carbon Steel by Slide Burnishing Process

Slide burnishing process, which is a surface severe plastic deformation technique, offers an attractive post-machining alternative due to its chip-less and relatively simple operations. The purpose of the present work is to investigate effects of initial turned surface roughness on the burnished surface roughness and hardness in slide burnishing. The carbon steel samples those have different roughness surfaces being treated were prepared by turning by varying the feed. Slide burnishing was then carried out by a silicon nitride ceramic ball that was loaded and fed on the turned surface of a rotating specimen using a lathe machine. It was found that the turned surfaces were smoothed drastically by the burnishing process, and that the Ra and Rz values were reduced at most by a factor of 52 and 21, respectively. However, the smoothing effect of burnishing has limit, and the limited maximum height roughness (Rz*) for burnishing smoothing increased under a higher burnishing force and with a larger ball diameter. When the Rz values of initial turned surfaces were less than the Rz*, the roughness of the burnished surfaces did not depend on the roughness of the initial turned surface and the burnishing force. There was no significant difference in the burnished microstructure and hardness under a specific burnishing force among the initial turned surface roughness, while a higher burnishing force caused a greater increase in surface hardness.

Enhancing fatigue performance of AZ31 magnesium alloy components fabricated by cold metal transfer-based wire arc directed energy deposition through LPB

Cold Metal Transfer-Based Wire Arc Directed Energy Deposition(CMT-WA-DED)presents a promising avenue for the rapid fabrication of components crucial to automotive,shipbuilding,and aerospace industries.However,the susceptibility to fatigue of CMT-WA-DED-produced AZ31 Mg alloy components has impeded their widespread adoption for critical load-bearing applications.In this study,a comprehensive investigation into the fatigue behaviour of WA-DED-fabricated AZ31 Mg alloy has been carried out and compared to commercially available wrought AZ31 alloy.Our findings indicate that the as-deposited parts exhibit a lower fatigue life than wrought Mg alloy,primarily due to poor surface finish,tensile residual stress,porosity,and coarse grain microstructure inherent in the WA-DED process.Low Plasticity Burnishing(LPB)treatment is applied to mitigate these issues,which induce significant plastic deformation on the surface.This treatment resulted in a remarkable improvement of fatigue life by 42%,accompanied by a reduction in surface roughness,grain refinement and enhancement of compressive residual stress levels.Furthermore,during cyclic deformation,WA-DED specimens exhibited higher plasticity and dislocation density compared to both wrought and WA-DED+LPB specimens.A higher fraction of Low Angle Grain Boundaries(LAGBs)in WA-DED specimens contributed to multiple crack initiation sites and convoluted crack paths,ultimately leading to premature failure.In contrast,wrought and WA-DED+LPB specimens displayed a higher percentage of High Angle Grain Boundaries(HAGBs),which hindered dislocation movement and resulted in fewer crack initiation sites and less complex crack paths,thereby extending fatigue life.These findings underscore the effectiveness of LPB as a post-processing technique to enhance the fatigue performance of WA-DED-fabricated AZ31 Mg alloy components.Our study highlights the importance of LPB surface treatment on AZ31 Mg components produced by CMT-WA-DED to remove surface defects,enabling their widespread use in load-bearing applications.

Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

In this study, a simple roller burnishing tool was made to operate burnishing processes on A356/5%SIC metal matrix composite fabricated by electromagnetic stir casting under different parameters. The effects of burnishing speed, burnishing force and number of burnishing passes on the surface roughness and tribological properties were measured. Scanning electron microscopy （SEM） graphs of the machined surface with PCD （insert-10） tool and roller burnished surface with tungsten carbide （WC） roller were taken into consider- ation to observe the surface finish of metal matrix composites. The mechanical properties （tensile strength, hardness, duc- tility） of A356/5%SIC metal matrix composites were studied for both unburnished samples and burnished samples. The results revealed that the roller burnished samples of A356/ 5%SIC led to the improvement in tensile strength, hardness and ductility. In order to find out the effects of roller bur- nishing process parameters on the surface roughness of A356/ 5%SIC metal matrix composite, response surface methodol- ogy （RSM） （Box-Behnken design） was used and a prediction model was developed relevant to average surface roughness using experimental data. In the range of process parameters, the result shows that roller burnishing speed increases, and surface roughness decreases, but on the other hand roller burnishing force and number of passes increase, and surface roughness increases. Optimum values of burnishing speed （1.5 m/s）, burnishing force （50 N） and number of passes （2） during roller burnishing of A356/5%SIC metal matrix com- posite to minimize the surface roughness （predicted 1.232 μm） have been found out. There was only 5.03% error in the experimental and modeled results of surface roughness.

Surface integrity of ball burnished bioresorbable magnesium alloy

Magnesium alloys are potential biodegradable and biocompatible implant materials because of their excellent biological properties. Recently, interest in these alloys as a promising alternative for temporary orthopedic implants has grown owing to their desirable biological, mechanical, and physical properties. However, the application of magnesium alloys is hindered by their rapid degradation and low corrosion resistance in physiological fluids, leading to the failure of implants. Thus, the current challenge is to enhance the corrosion resistance and control the degradation rate of magnesium under physiological conditions. The rapid degradation of magnesium alloys can be controlled by improving their surface integrity, such as surface roughness and microhardness. The present study aims to improve the surface integrity of the Mg Ze41A alloy by the ball burnishing technique. The surface roughness improved by 94.90% from 0.941 μm to 0.048 μm with a burnishing force of 50 N, burnishing speed of 1 300 r/min, burnishing feed of 130 mm/min, and three passes. Similarly, the microhardness improved by 50.62% from 75.2 HV to 113.27 HV with a burnishing force of 60 N, burnishing speed of 1 100 r/min, burnishing feed of 100 mm/min, and five passes. The variations in microhardness, which were observed up to 400 μm beneath the surface, exhibited a linear nature. These variations may be attributed to the movement of dislocations, formation of new dislocations, nanocrystal structures, metastable phases and subgrains, and lattice distortion or grain refinement. The surface features obtained from optical images demonstrated the fundamental mechanisms involved in the ball burnishing process. The concept of burnishing maps and zones will assist in the design of the ball burnishing parameters of a material with an equivalent yield strength of 140 MPa. The significant improvement in the surface integrity of the Mg Ze41A alloy by the ball burnishing technique is expected to improve its functional performance.

Fracture Morphologies of Advanced High Strength Steel During Deformation

The fracture morphologies of several advanced high-strength steels （DP590, DP780, DP980, Ml180, and M1300） formed in uniaxial tension and piercing were observed by scanning electron microscope, and then quantitatively analyzed by image processing technique. The tension-induced fractographs are dominated by obvious uniform or bimodal size dimples, while shearing-induced fractographs have smooth surfaces and few dimples. The fracture zone of higher grade DP steels is smoother. As for M1180 and M1300, the fracture zones consist of very small dimples and smooth brittle surfaces. The dimple size of M1300（ ,- 1.2 tm） is smaller than that of M1180（ 1.6 tm）. Moreover, in the tensile fracture, the quantitative correlation between average dimple diameter （d） and tensile strength （a） can be represented by d = 10,502.32a-121. However, the relation between dimple density and tensile strength is not monotonic due to the appearance of bimodal size dimples with increase of tensile strength. For shearing-induced fracture during piercing, the fitted empirical model between the percentage of burnish zone （f） and tensile strength can be described asf --- 239.9a-＇36.