Advertisement

Crack resistance enhancement of joint bar holes by slide diamond burnishing using new tool equipment

  • J. T. MaximovEmail author
  • G. V. Duncheva
  • A. P. Anchev
  • V. P. Dunchev
ORIGINAL ARTICLE

Abstract

The article presents a new technology for joint bar holes processing. Joint bars are components of rail bolted joints, which are a critical place for nucleation and propagation of fatigue cracks caused by cyclic loading due to passing trains. The probability of corner cracks arising, starting from the internal edges of the joint bar holes, is proven using the finite element method (FEM). On this basis, the necessity for a new technology for the enhancement of crack resistance of joint bar holes is grounded. The technology comprises slide diamond burnishing (SDB) as finishing of these holes. New tool equipment is developed including a combined cutting tool and an SDB device with elastic beam in order to set the necessary burnishing force. The equipment is intended for milling machine tools and machining centers. The optimal parameters of both cutting and SDB processes are obtained through planned experiments, regression analyses, genetic algorithm, and FE analyses. The distribution of the introduced beneficial residual hoop stresses is found by conducting a FE analysis of the SDB process. These stresses delay the nucleation and growth of fatigue cracks initiating in the hole surface. Both microscope analysis and fatigue tests prove this technology’s advantage, expressed in the increased crack resistance of joint bar holes.

Keywords

Rail bolted joint Crack resistance Slide diamond burnishing Residual stresses FEM analysis Fatigue test 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Acknowledgments

The authors would like to acknowledge Dr Yosiph Mitev for fatigue test specimen preparation.

Funding information

This work was financially supported by the Bulgarian Ministry of Education and Science and the Technical University of Gabrovo under Contract No 1802M.

References

  1. 1.
    Talamini B, Jeong DY, Gordon J (2007) Estimation of the fatigue life of railroad joint bars. In: Proceedings of joint rail conference & internal combustion engine spring technical conference. Pueblo, Colorado, USA, March 13–16, 2007, 1–10Google Scholar
  2. 2.
    Jeong DY, Bruzek R, Tajaddini A (2014) Engineering studies on joint bar integrity. Part I: field surveys and observed failure modes. In: The 2014 joint rail conference IRS2014. Colorado Springs, CO, USA, April 2-4, 2014Google Scholar
  3. 3.
    Carolan ME, Jeong DY, Perlman AB (2014) Engineering studies on joint bar integrity. Part II: finite element analysis. In: The 2014 joint rail conference IRS2014. Colorado Springs, CO, USA, April 2-4, 2014Google Scholar
  4. 4.
    Reid L (1993) Beneficial residual stresses at bolt holes by cold expansion. In: Kalker JJ (ed) Rail quality and maintenance for modern railway operation. Kluwer Academic Publishers, Netherlands, pp 337–347CrossRefGoogle Scholar
  5. 5.
    Duncheva GV, Maximov JT (2013) A new approach to enhancement of fatigue life of rail-end-bolt holes. Eng Fail Anal 29:167–179CrossRefGoogle Scholar
  6. 6.
    Maximov JT, Duncheva GV, Amudjev IM, Anchev AP, Ganev N (2017) A new approach for pre-stressing of rail-end-bolt holes. Proc IMechE, Part C: J Mech Eng Sci 231(12):2284–2290CrossRefGoogle Scholar
  7. 7.
    Maximov JT, Duncheva GV, Anchev AP, Amudjev IM, Kuzmanov VT (2014) Enhancement of fatigue life of rail-end-bolt holes by slide diamond burnishing. Eng Solid Mech 2(4):247–264CrossRefGoogle Scholar
  8. 8.
    Ecoroll Catalogue “Tools and Solutions for Metal Surface Improvement” (2006) Ecoroll Corporation Tool Technology, USAGoogle Scholar
  9. 9.
    Korzynski M (2009) A model of smoothing slide ball-burnishing and an analysis of the parameter interaction. J Mater Process Technol 209(1):625–633CrossRefGoogle Scholar
  10. 10.
    Korzynski M (2007) Modeling and experimental validation of the force-surface roughness relation for smoothing burnishing with a spherical tool. Int J Mach Tools Manuf 47(12):1956–1964CrossRefGoogle Scholar
  11. 11.
    Korzynsky M (2013) Slide diamond burnishing. In: Korzynski M (ed) Nonconventional finishing technologies. Polish Scientific Publishers, Warsaw, pp 9–33Google Scholar
  12. 12.
    Maximov JT, Anchev AP, Dunchev VP, Ganev N, Duncheva GV, Selimov KF (2017) Effect of slide burnishing basic parameters on fatigue performance of 2024-T3 high-strength aluminium alloy. Fatigue Fract Engng Mater Struct 40(11):1893–1904CrossRefGoogle Scholar
  13. 13.
    Bounouara A, Hamadache H, Amirat A (2018) Investigation on the effect of ball burnishing on fracture toughness in spiral API X70 pipeline steel. Int J Adv Manuf Technol 94(9–12):4543–4551CrossRefGoogle Scholar
  14. 14.
    Tang J, Luo HY, Zhang (2017) Enhancing the surface integrity and corrosion resistance of Ti-6Al-4V titanium alloy through cryogenic burnishing. Int J Adv Manuf Technol 88(9–12):2785–2793CrossRefGoogle Scholar
  15. 15.
    He D, Wang B, Zhang J, Liao S, Deng LW (2018) Investigation of interference effects on the burnishing process. Int J Adv Manuf Technol 95(1–4):1–10CrossRefGoogle Scholar
  16. 16.
    El-Axir MH, Othman OM, Abodiena AM (2008) Study on the inner surface finishing of aluminium alloy 2014 by ball burnishing process. J Mater Process Technol 202:435–442CrossRefGoogle Scholar
  17. 17.
    El-Axir MH, Othman OM, Abodiena AM (2008) Improvements in out-of-roundness and microhardness of inner surfaces by internal ball burnishing. J Mater Process Technol 196(1–3):120–128CrossRefGoogle Scholar
  18. 18.
    Akkurt A (2011) Comparison of roller burnishing method with other hole surface finishing processes applied on AISI 304 austenitic stainless steel. J Mater Eng Perform 20(6):960–968CrossRefGoogle Scholar
  19. 19.
    Akkurt A, Kurt A, Ozdemir A, Seker U (2014) Comparison of hole surface finishing processes with roller burnishing method applied in copper materials. Gazi Univ J Sci 27(1):721–734Google Scholar
  20. 20.
    Pa PS (2010) Continuous finishing processes using a combination of burnishing and electrochemical finishing on bore surfaces. Int J Adv Manuf Technol 49(1–4):147–154CrossRefGoogle Scholar
  21. 21.
    Korzynski M (2009) Relief making on bearing sleeve surface by eccentric burnishing. J Mater Process Technol 209:131–138CrossRefGoogle Scholar
  22. 22.
    Bulgarian National Standard EN 13674–1 (2011) Railway applications – Track – Rail – Part 1: Vignole railway rails 46 kg/m and aboveGoogle Scholar
  23. 23.
    Cai W, Wen Z, Jin X, Zhai W (2007) Dynamic stress analysis of rail joint with height difference defect using finite element method. Eng Fail Anal 14:1488–1499CrossRefGoogle Scholar
  24. 24.
    ABAQUS 6.12 Theory Manual (2015) Rising Sun Mills, 166 Valley Street Providence, RI 02909–2499Google Scholar
  25. 25.
    Sai WB, Lebrun JL (2003) Influence of finishing by burnishing on surface characteristics. J Mater Eng Perform 12(1):37–40CrossRefGoogle Scholar
  26. 26.
    Maximov JT, Duncheva GV, Anchev AP, Ganev N, Amudjev IM, Dunchev VP (2018) Effect of slide burnishing method on the surface integrity of AISI 316Ti chromium-nickel steel. J Braz Soc Mech Sci Eng 40(194).  https://doi.org/10.1007/s40430-018-1135-3
  27. 27.
    Vedrtnam A (2019) Novel treatment methods for improving fatigue behavior of laminated glass. Compos Part B: Eng 167:180–198CrossRefGoogle Scholar
  28. 28.
    Vedrtnam A (2019) Novel method for improving fatigue behavior of carbon fiber reinforced epoxy composite. Compos Part B: Eng 157:305–321CrossRefGoogle Scholar
  29. 29.
    Vedrtnam A, Singh G, Kumar A (2018) Optimizing submerged arc welding process using response surface methodology. Defense Technol 14(3):204–212CrossRefGoogle Scholar
  30. 30.
    Vedrtnam A, Pawar SJ (2018) Experimental and simulation studies on flexural strength of laminated glass using ring-on-ring and three-point bending test. Proc IMechE Part C J Mech Eng Sci 232(21):3930–3941CrossRefGoogle Scholar
  31. 31.
    Vuchkov IN, Vuchkov II (2009) QStatLab professional, v. 5.5—statistical quality control software. User’s Manuel, SofiaGoogle Scholar
  32. 32.
    Yen YC, Sartkulvanich P, Altan T (2005) Finite element modeling of roller burnishing process. CIRP Annals – Manuf Technol 54(1):237–240CrossRefGoogle Scholar
  33. 33.
    Sartkulvanich P, Altan T, Jasso F, Rodriguez C (2007) Finite element modeling of hard roller burnishing: an analysis on the effects of process parameters upon surface finish and residual stresses. J Manuf Sci Eng 129(4):705–716CrossRefGoogle Scholar
  34. 34.
    Maximov JT, Duncheva GV (2012) Finite element analysis and optimization of spherical motion burnishing of low-alloy steel. Proc. IMechE Part C: J Mech Eng Sci 226(1):161–176CrossRefGoogle Scholar
  35. 35.
    Maximov JT, Duncheva GV, Anchev AP, Ichkova MD (2014) Modelling of strain hardening behaviour of 2024T3 aluminium alloy at room and high temperatures. Comput Mater Sci 83:381–393CrossRefGoogle Scholar
  36. 36.
    Maximov JT, Anchev AP, Duncheva GV (2015) Modeling of the friction in tool-workpiece system in diamond burnishing process. Coupled Syst Mech 4(4):279–295CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • J. T. Maximov
    • 1
    Email author
  • G. V. Duncheva
    • 1
  • A. P. Anchev
    • 1
  • V. P. Dunchev
    • 1
  1. 1.Technical University of GabrovoGabrovoBulgaria

Personalised recommendations