Skip to main content
SpringerLink
Log in

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

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

In this study, the effect of the roller burnishing process on surface integrity and fatigue performance of AISI 4340 steel, which had been used in the cylinder of pressure intensifier, was investigated. The effects of burnishing depth, feed rate, and burnishing speed parameters of the roller burnishing process were examined. The roller burnishing process was applied to standard fatigue test specimens. After burnishing, surface roughness was measured, and fatigue life was determined by axial fatigue tests. The novelty of the study is the investigation of the axial fatigue performance of AISI 4340 steel at a specific stress ratio. Optimum levels of roller burnishing process parameters were determined for the lowest surface roughness and the highest fatigue life. The surface roughness was reduced from 2.98 to 0.51 µm. It has been observed that the burnishing depth was the highest effect on the surface roughness at 78%. The most effective parameter on the fatigue life was the feed rate with a contribution ratio of 57%. Up to 70% improvement was obtained in the fatigue life of AISI 4340 steel.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

Availability of data and material

Not applicable.

Code availability

Not applicable.

References

  1. Boozarpoor M, Teimouri R (2021) Parametric study of multi-roller rotary burnishing process. Int J Light Mater Manuf 4:179–194. https://doi.org/10.1016/j.ijlmm.2020.10.001

    Article  Google Scholar 

  2. Zhang P, Lindemann J (2005) Effect of roller burnishing on the high cycle fatigue performance of the high-strength wrought magnesium alloy AZ80. Scr Mater 52:1011–1015. https://doi.org/10.1016/j.scriptamat.2005.01.026

    Article  Google Scholar 

  3. Akkurt A, Abdullah K, ÖZDEMİR A, ŞEKER U (2014) Comparison of hole surface finishing processes with roller burnishing method applied in copper materials. Gazi Univ J Sci 27(1):721–734

    Google Scholar 

  4. El-Axir MH (2000) Investigation into roller burnishing. Int J Mach Tools Manuf 40:1603–1617. https://doi.org/10.1016/S0890-6955(00)00019-5

    Article  Google Scholar 

  5. Hua Y, Liu Z, Wang B, Hou X (2019) Surface modification through combination of finish turning with low plasticity burnishing and its effect on fatigue performance for Inconel 718. Surf Coatings Technol 375:508–517. https://doi.org/10.1016/j.surfcoat.2019.07.057

    Article  Google Scholar 

  6. Zhuang W, Liu Q, Djugum R, Sharp PK, Paradowska A (2014) Deep surface rolling for fatigue life enhancement of laser clad aircraft aluminium alloy. Appl Surf Sci 320:558–562. https://doi.org/10.1016/j.apsusc.2014.09.139

    Article  Google Scholar 

  7. Avilés R, Albizuri J, Rodríguez A, López De Lacalle LN (2013) Influence of low-plasticity ball burnishing on the high-cycle fatigue strength of medium carbon AISI 1045 steel. Int J Fatigue 55:230–244. https://doi.org/10.1016/j.ijfatigue.2013.06.024

    Article  Google Scholar 

  8. Livatyali H, Has E, Türköz M (2020) Prediction of residual stresses in ball burnishing TI6AL4V thin sheets. Int J Adv Manuf Technol 110:1083–1093. https://doi.org/10.1007/s00170-020-05837-2

    Article  Google Scholar 

  9. Duncheva GV, Maximov JT, Dunchev VP, Anchev AP, Atanasov TP, Capek J (2020) Single toroidal roller burnishing of 2024-T3 Al alloy implemented as mixed burnishing process. Int J Adv Manuf Technol 111:3559–3570. https://doi.org/10.1007/s00170-020-06350-2

    Article  Google Scholar 

  10. Duncheva GV, Maximov JT, Dunchev VP, Anchev AP, Atanasov TP, Capek J (2021) Improvement in fatigue performance of 2024-T3 Al Alloy via single toroidal roller burnishing, international. J Mater Eng Perform 30:2256–2266. https://doi.org/10.1007/s11665-021-05535-4

    Article  Google Scholar 

  11. Gardin C, Courtin S, Bertheau D, Bezine G, Ben Hadj Hamouda H (2007) The influence of roller burnishing on the fatigue crack propagation in notched round bars—experimental observations under three-point bending. Fatigue Fract Eng Mater Struct 30(4):342–350

    Article  Google Scholar 

  12. Mohamed OAO, Wagne L (2016) Optimizing the process parameters and investigating the influence of shot peening and roller burnishing on surface layer properties and fatigue performance of Al 6061 T4. Sohag J Sci 1(1):65–68. https://doi.org/10.18576/sjs/010108

    Article  Google Scholar 

  13. Zhang P, Lindemann J, Ding WJ, Leyens C (2010) Effect of roller burnishing on fatigue properties of the hot-rolled Mg–12Gd–3Y magnesium alloy. Mater Chem Phys 124:835–840. https://doi.org/10.1016/j.matchemphys.2010.07.070

    Article  Google Scholar 

  14. Babu PR, Prasad TS, Raju AVS, Babu AJ (2009) Effect of internal roller burnishing on surface roughness and surface hardness of mild steel. J Sci Ind Res 68(2009):29–31

    Google Scholar 

  15. John MRS, Vinayagam BBBK (2017) Optimisation of internal roller burnishing process in CNC machining center using response surface methodology. J Braz Soc Mech Sci Eng 39:4045–4057. https://doi.org/10.1007/s40430-017-0871-0

    Article  Google Scholar 

  16. Boozarpoor M, Elyasi M, Hosseinzadeh M (2018) An investigation of the surface quality of burnished AISI 4340 steel. Proc Inst Mech Eng Part E J Process Mech Eng 232(3):299–313. https://doi.org/10.1177/0954408917694215

    Article  Google Scholar 

  17. Cobanoglu T, Ozturk S (2014) Proceedings of the institution of mechanical engineers. Part B J Eng Manuf. https://doi.org/10.1177/0954405414527962

    Article  Google Scholar 

  18. Saldaña-robles A, Plascencia-mora H, Aguilera-gómez E, Saldaña-robles A, Marquez-herrera A, Angel J, Peña D (2018) Surface & coatings technology influence of ball-burnishing on roughness, hardness and corrosion resistance of AISI 1045 steel. Surf Coat Technol 339:191–198. https://doi.org/10.1016/j.surfcoat.2018.02.013

    Article  Google Scholar 

  19. Rodríguez A, De Lacalle LNL, Celaya A, Lamikiz A, Albizuri J (2012) Surface & coatings technology surface improvement of shafts by the deep ball-burnishing technique. Surf Coat Technol 206:2817–2824. https://doi.org/10.1016/j.surfcoat.2011.11.045

    Article  Google Scholar 

  20. Okada M, Suenobu S, Watanabe K, Yamashita Y, Asakawa N (2015) Mechatronics development and burnishing characteristics of roller burnishing method with rolling and sliding effects. Mechatronics 29:110–118. https://doi.org/10.1016/j.mechatronics.2014.11.002

    Article  Google Scholar 

  21. López de Lacalle LN, Lamikiz A, Sánchez JA, Arana JL (2007) The effect of ball burnishing on heat-treated steel and inconel 718 milled surfaces. Inter J Adv Manuf Techn 32(9–10):958–968. https://doi.org/10.1007/s00170-005-0402-5

    Article  Google Scholar 

  22. Sequera A, Fu CH, Guo YB, Wei XT (2014) surface integrity of inconel 718 by ball burnishing. J Mat Eng Perform 23(9):3347–3353. https://doi.org/10.1007/s11665-014-1093-6

    Article  Google Scholar 

  23. Qiao Y, Chen H, Qi K, Guo P (2020) Research on mechanical properties of 210cr12 shaft surface processed with rolling. Coatings 10(7):611. https://doi.org/10.3390/coatings10070611

    Article  Google Scholar 

  24. Prasad KA, John MRS (2021) Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology. J Braz Soc Mech Sci Eng 43:1–12. https://doi.org/10.1007/s40430-021-03069-3

    Article  Google Scholar 

  25. Maximov JT, Duncheva GV, Anchev AP, Dunchev VP, Ichkova MD (2020) Improvement in fatigue strength of 41Cr4 steel through slide diamond burnishing. J Braz Soc Mech Sci Eng 42:1–20. https://doi.org/10.1007/s40430-020-02276-8

    Article  Google Scholar 

  26. Avilés A, Avilés R, Albizuri J, Pallarés-Santasmartas L, Rodríguez A (2019) Effect of shot-peening and low-plasticity burnishing on the high-cycle fatigue strength of DIN 34CrNiMo6 alloy steel. Int J Fatigue 119:338–354. https://doi.org/10.1016/j.ijfatigue.2018.10.014

    Article  Google Scholar 

  27. All Metals & Forge Group https://steelforge.com/alloy-steel-4340/ 2021 (Accessed 21 September 2021)

  28. Dieter GE, Bacon D (1976) Mechanical metallurgy, vol 3. McGraw-hill, New York

    Google Scholar 

  29. Ugural AC, Fenster SK (2011) Advanced mechanics of materials and applied elasticity, Pearson education

  30. John F (1997) Harvey, theory & design of pressure vessels. Van Nostrand Reinhold Co., New York

    Google Scholar 

  31. Nguyen T-T, Le X-B (2019) Optimization of roller burnishing process using Kriging model to improve surface properties. Proc Inst Mech Eng Part B J Eng Manuf 233:2264–2282. https://doi.org/10.1177/0954405419835295

    Article  Google Scholar 

  32. Collins JA, Busby HR, Staab GH (2009) Mechanical design of machine elements and machines: a failure prevention perspective. John Wiley

    Google Scholar 

Download references

Acknowledgements

The work presented in this article was conducted as the Master’s thesis of Mevlüt Aydın at the Department of Mechanical Engineering of Konya Technical University, being sponsored by the Research Project Unit (BAP) of Konya Technical University under Project Number 201010023. Konya Technical University is profoundly acknowledged.

Funding

This article was supported by the Research Project Unit (BAP) of Konya Technical University under project no 201010023. Konya Technical University is profoundly acknowledged.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Konya Technical University, Konya, Turkey

    Mevlüt Aydın & Mevlüt Türköz

Authors
  1. Mevlüt Aydın
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mevlüt Türköz
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

This paper was generated from the Master’s thesis the author Mr. Mevlüt Aydın conducted and Dr. Mevlüt Türköz supervised at the Department of Mechanical Engineering, Konya Technical University.

Corresponding author

Correspondence to Mevlüt Aydın.

Ethics declarations

Conflict of interest

The authors have no relevant financial or non-financial interest to disclose.

Ethical approval

Not applicable.

Consent to participate

The Authors accept to participate.

Consent for publication

The Authors accept for publication.

Additional information

Technical Editor: Izabel Fernanda Machado.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Aydın, M., Türköz, M. A study on the effect of the roller burnishing process on the axial fatigue performance and surface integrity of AISI 4340 steel. J Braz. Soc. Mech. Sci. Eng. 44, 224 (2022). https://doi.org/10.1007/s40430-022-03536-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-022-03536-5

Keywords

Search

Navigation