Advertisement

A predictive approach to investigating effects of ultrasonic-assisted burnishing process on surface performances of shaft targets

  • Zhihua Liu
  • Mengjian Yang
  • Jia DengEmail author
  • Meng ZhangEmail author
  • Qilong Dai
ORIGINAL ARTICLE
  • 21 Downloads

Abstract

The ultrasonic-assisted burnishing process (UABP) is an effective surface finishing technology that obtains compressive residual stress and surface work hardening and decreases surface roughness. A three-dimensional explicit nonlinear finite element model (FEM) of the UABP on a shaft specimen was established and calibrated in this paper. A comparison of finite element (FE) simulation results with experimental data showed good agreement in terms of the predicted residual stress in both tangential and axial directions. The established FEM explores the influence of treatment parameters, such as ball diameters, static forces, spindle speeds, ultrasonic frequencies, vibration amplitudes, and friction coefficients, on the resultant profile of residual stress and equivalent plastic deformation. This dynamic explicit FE method is an effective approach to investigate the UABP, to relate the processing parameters with surface integrity, including the depth of residual stress and work hardening of objective surfaces, and to guide the design of the UABP parameters.

Keywords

Ultrasonic-assisted burnishing process Predictive approach Shaft targets Residual stress 18CrNiMo7-6 steel 

Notes

Acknowledgments

The authors would like to acknowledge the financial supports from the China National Natural Science Fund (11602227).

References

  1. 1.
    Zhao J, Liu ZQ (2016) Investigations of ultrasonic frequency effects on surface deformation in rotary ultrasonic roller burnishing Ti-6Al-4V. Mater Des 107:238–249.  https://doi.org/10.1016/j.matdes.2016.06.024 CrossRefGoogle Scholar
  2. 2.
    Teimouri R, Amini S, Guagliano M (2019) Analytical modeling of ultrasonic surface burnishing process: evaluation of residual stress field distribution and strip deflection. Mat Sci Eng A-Struct 747:208–224.  https://doi.org/10.1016/j.msea.2019.01.007 CrossRefGoogle Scholar
  3. 3.
    Zhang M, Liu ZH, Deng J, Yang MJ, Dai QL, Zhang TZ (2019) Optimum design of compressive residual stress field caused by ultrasonic surface burnishing with a mathematical model. Appl Math Model 76:800–831.  https://doi.org/10.1016/j.apm.2019.07.009 MathSciNetCrossRefGoogle Scholar
  4. 4.
    Travieso-Rodriguez JA, Gomez-Gras G, Dessein G, Carrillo F, Alexis J, Jorba-Peiro J, Aubazac N (2015) Effects of a ball-burnishing process assisted by vibrations in G10380 steel specimens. Int J Adv Manuf Technol 81:1757–1765.  https://doi.org/10.1007/s00170-015-7255-3 CrossRefGoogle Scholar
  5. 5.
    Zhang QL, Hu ZQ, Su WW, Zhou HL, Liu CX, Yang YL, Qi XW (2017) Microstructure and surface properties of 17-4PH stainless steel by ultrasonic surface burnishing technology. Surf Coat Technol 321:64–73.  https://doi.org/10.1016/j.surfcoat.2017.04.052 CrossRefGoogle Scholar
  6. 6.
    Liu CS, Liu DX, Zhang XH, He GY, Xu XC, Ao N, Ma A, Liu D (2019) On the influence of ultrasonic surface burnishing process on surface integrity and fatigue performance of Ti-6Al-4V alloy. Surf Coat Technol 370:24–34.  https://doi.org/10.1016/j.surfcoat.2019.04.080 CrossRefGoogle Scholar
  7. 7.
    Ye H, Sun X, Liu Y, Rao XX, Gu Q (2019) Effect of ultrasonic surface burnishing process on mechanical properties and corrosion resistance of AZ31B mg alloy. Surf Coat Technol 372:288–298.  https://doi.org/10.1016/j.surfcoat.2019.05.035 CrossRefGoogle Scholar
  8. 8.
    Skalski K, Morawski A, Przybylski W (1995) Analysis of contact elastic–plastic strains during the process of burnishing. Int J Mech Sci 37:461–472.  https://doi.org/10.1016/0020-7403(94)00083-V CrossRefzbMATHGoogle Scholar
  9. 9.
    Salahshoor M, Guo YB (2013) Process mechanics in ball burnishing biomedical magnesium–calcium alloy. Int J Adv Manuf Technol 64(1–4):133–144.  https://doi.org/10.1007/s00170-012-4024-4 CrossRefGoogle Scholar
  10. 10.
    Stalin John MR, Welsoon Wilson A, Prasad Bhardwaj A, Abraham A, Vinayagam BK (2016) An investigation of ball burnishing process on CNC lathe using finite element analysis. Simul Model Pract Theory 62:88–101.  https://doi.org/10.1016/j.simpat.2016.01.004 CrossRefGoogle Scholar
  11. 11.
    Sayahi M, Sghaier S, Belhadjsalah H (2013) Finite element analysis of ball burnishing process: comparisons between numerical results and experiments. Int J Adv Manuf Technol 67:1665–1673.  https://doi.org/10.1007/s00170-012-4599-9 CrossRefGoogle Scholar
  12. 12.
    Liu Y, Zhao X, Wang D (2014) Effective FE model to predict surface layer characteristics of ultrasonic surface burnishing with experimental validation. J Mater Sci Technol 30(6):627–636.  https://doi.org/10.1179/1743284713Y.0000000396 CrossRefGoogle Scholar
  13. 13.
    Mohammadi F, Sedaghati R, Bonakdar A (2014) Finite element analysis and design optimization of low plasticity burnishing process. Int J Adv Manuf Technol 70:1337–1354.  https://doi.org/10.1007/s00170-013-5406-y CrossRefGoogle Scholar
  14. 14.
    Manouchehrifar A, Alasvand K (2012) Finite element simulation of deep burnishing and evaluate the influence of parameters on residual stress. 5th WSEAS international conference: 121-127. https://www.researchgate.net/publication/268436071
  15. 15.
    Courtin S, Henaff-Gardin C, Bezine G (2003) Finite element simulation of roller burnishing in crankshafts. 2003 wit press. https://www.witpress.com/elibrary/wit-transactions-on-engineering-sciences/39/1451
  16. 16.
    Perenda J, Trajkovski J, Zerovnik A, Prebil I (2016) Modeling and experimental validation of the surface residual stresses induced by deep burnishing and presetting of a torsion bar. Int J Mater Form 9(4):435–448.  https://doi.org/10.1007/s12289-015-1230-2 CrossRefGoogle Scholar
  17. 17.
    Bougharriou A, Sai K, Bouzid W (2010) Finite element modelling of burnishing process. Mater Technol 25(1):56–62.  https://doi.org/10.1179/175355509X387110 CrossRefGoogle Scholar
  18. 18.
    Kamgaing Souop L, Daidie A, Landon Y, Senatore J, Ritou M (2019) Investigation of aluminum alloy properties during helical roller burnishing through finite element simulations and experiments. Advances on Mechanics, Design Engineering and Manufacturing II LNME:440–450.  https://doi.org/10.1007/978-3-030-12346-8_43 CrossRefGoogle Scholar
  19. 19.
    Song HX, Kong ZY, Sun WZ (2014) Research on processing tool in ultrasonic gear flank enhancement. Comput Simul 31(2):307–319Google Scholar
  20. 20.
    Gao QQ (2014) Design and research of ultrasonic nanometer precision burnishing device. Dissertation, East China Jiaotong UniversityGoogle Scholar
  21. 21.
    Balland P, Tabourot L, Degre F, Moreau V (2013) An investigation of the mechanics of roller burnishing through finite element simulation and experiments. Int J Mach Tool Manu 65:29–36.  https://doi.org/10.1016/j.ijmachtools.2012.09.002 CrossRefGoogle Scholar
  22. 22.
    Pang JZ, Li BZ, Yang JG, Zhou ZX (2011) Temperature simulation in high-speed grinding by using deform-3D. Manuf Process Technol 189-193:1849–1853.  https://doi.org/10.4028/www.scientific.net/AMR.189-193.1849 CrossRefGoogle Scholar
  23. 23.
    Zhang M, Zhang YX, Zhou Y (2019) Theoretical and experimental analysis of compressive residual stress field on 6061 aluminum alloy after ultrasonic surface rolling process. P I Mech Eng C-J Mec 233(15):5363–5376CrossRefGoogle Scholar
  24. 24.
    Teimouri R, Amini S (2016) Analytical modeling of ultrasonic surface burnishing process: evaluation of through depth localized strain. Int J Mech Sci 151:118–132.  https://doi.org/10.1016/j.ijmecsci.2018.11.008 CrossRefGoogle Scholar
  25. 25.
    Abouridouane M, Laschet G, Kripak V, Texeira A, Dierdorf J, Prahl P, Klocke F (2017) Cutting simulations of two gear steels with microstructure dependent material laws. Procedia CIRP 58:549–554.  https://doi.org/10.1016/j.procir.2017.03.332 CrossRefGoogle Scholar
  26. 26.
    Azimi M, Mirjavadi SS, Asli SA (2016) Investigation of mesh sensitivity influence to determine crack characteristic by finite element methods. J Fail Anal Prev 16(3):506–512.  https://doi.org/10.1007/s11668-016-0117-y CrossRefGoogle Scholar
  27. 27.
    Azimi M, Mirjavadi SS, Asli SA, Hamouda AMS (2017) Fracture analysis of a special cracked lap shear (CLS) specimen with utilization of virtual crack closure technique (VCCT) by finite element methods. J Fail Anal Prev 17(2):304–314.  https://doi.org/10.1007/s11668-017-0243-1 CrossRefGoogle Scholar
  28. 28.
    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 129:705–716.  https://doi.org/10.1115/1.2738121 CrossRefGoogle Scholar
  29. 29.
    Azimi M, Mirjavadi SS, Salandari-Rabori (2017) Effect of temperature on microstructural evolution and subsequent enhancement of mechanical properties in a backward extruded magnesium alloy. Int J Adv Manuf Technol 95:3155–3166.  https://doi.org/10.1007/s00170-017-1343-5 CrossRefGoogle Scholar
  30. 30.
    Zhang M, Deng J, Liu ZH, Zhou Y (2019) Investigation into contributions of static and dynamic loads to compressive residual stress fields caused by ultrasonic surface rolling. Int J Mech Sci 163:105144.  https://doi.org/10.1016/j.ijmecsci.2019.105144 CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2020

Authors and Affiliations

  1. 1.School of Mechanical EngineeringZhengzhou UniversityZhengzhouChina
  2. 2.Henan Key Engineering Laboratory for Anti-fatigue Manufacturing TechnologyZhengzhouChina
  3. 3.School of Mechanics and Engineering SciencesZhengzhou UniversityZhengzhouChina

Personalised recommendations